U.S. patent application number 15/521681 was filed with the patent office on 2017-08-31 for electrode catalyst for fuel cell, method for producing the same, electrode catalyst layer for fuel cell comprising the catalyst, and membrane electrode assembly for fuel cell and fuel cell using the catalyst or the catalyst layer.
This patent application is currently assigned to NISSAN MOTOR CO., LTD. IP Dept. The applicant listed for this patent is NIPPON STEEL & SUMIKIN CHEMICAL CO., LTD., NISSAN MOTOR CO., LTD.. Invention is credited to Tetsuya MASHIO, Shinichi TAKAHASHI.
Application Number | 20170250432 15/521681 |
Document ID | / |
Family ID | 55857223 |
Filed Date | 2017-08-31 |
United States Patent
Application |
20170250432 |
Kind Code |
A1 |
TAKAHASHI; Shinichi ; et
al. |
August 31, 2017 |
ELECTRODE CATALYST FOR FUEL CELL, METHOD FOR PRODUCING THE SAME,
ELECTRODE CATALYST LAYER FOR FUEL CELL COMPRISING THE CATALYST, AND
MEMBRANE ELECTRODE ASSEMBLY FOR FUEL CELL AND FUEL CELL USING THE
CATALYST OR THE CATALYST LAYER
Abstract
Provided is a catalyst for fuel cell which has a high catalytic
activity and enables maintaining the high catalytic activity.
Disclosed is an electrode catalyst for fuel cell comprising a
catalyst carrier containing carbon as a main component and a
catalytic metal supported on the catalyst carrier, wherein the
catalyst has the R' (D'/G intensity ratio) of 0.6 or less, which is
the ratio of D' band peak intensity (D' intensity) measured in the
vicinity of 1620 cm.sup.-1 relative to G band peak intensity (G
intensity) measured in the vicinity of 1580 cm.sup.-1 by Raman
spectroscopy, and the volume ratio of a water vapor adsorption
amount relative to a nitrogen adsorption amount at a relative
pressure of 0.5 in adsorption isotherm is 0.15 or more and 0.30 or
less.
Inventors: |
TAKAHASHI; Shinichi;
(Kanagawa, JP) ; MASHIO; Tetsuya; (Kanagawa,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NISSAN MOTOR CO., LTD.
NIPPON STEEL & SUMIKIN CHEMICAL CO., LTD. |
Yokohama-shi, Kanagawa
Tokyo |
|
JP
JP |
|
|
Assignee: |
NISSAN MOTOR CO., LTD. IP
Dept
Yokohama-shi, Kanagawa
JP
NIPPON STEEL & SUMIKIN CHEMICAL CO., LTD.
Chiyoda-ku, Tokyo
JP
|
Family ID: |
55857223 |
Appl. No.: |
15/521681 |
Filed: |
October 8, 2015 |
PCT Filed: |
October 8, 2015 |
PCT NO: |
PCT/JP2015/078617 |
371 Date: |
April 25, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M 8/1004 20130101;
H01M 4/86 20130101; H01M 8/1018 20130101; Y02E 60/50 20130101; H01M
4/8828 20130101; H01M 2300/0082 20130101; Y02P 70/50 20151101; H01M
2008/1095 20130101; H01M 4/8668 20130101; H01M 4/8803 20130101;
H01M 4/88 20130101; H01M 4/92 20130101; H01M 4/926 20130101 |
International
Class: |
H01M 8/1018 20060101
H01M008/1018; H01M 8/1004 20060101 H01M008/1004; H01M 4/88 20060101
H01M004/88; H01M 4/86 20060101 H01M004/86; H01M 4/92 20060101
H01M004/92 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 29, 2014 |
JP |
2014-220579 |
Claims
1. An electrode catalyst for fuel cell comprising a catalyst
carrier containing carbon as a main component and a catalytic metal
supported on the catalyst carrier, wherein the catalyst has the R'
(D'/G intensity ratio) of 0.6 or less, which is the ratio of D'
band peak intensity (D' intensity) measured in the vicinity of 1620
cm.sup.-1 relative to G band peak intensity (G intensity) measured
in the vicinity of 1580 cm.sup.-1 by Raman spectroscopy, and the
volume ratio of a water vapor adsorption amount relative to a
nitrogen adsorption amount at a relative pressure of 0.5 in
adsorption isotherm is 0.15 or more and 0.30 or less.
2. The electrode catalyst for fuel cell according to claim 1,
wherein the BET specific surface area is 900 m.sup.2/g catalyst or
more.
3. An electrode catalyst layer for fuel cell comprising the
electrode catalyst for fuel cell set forth in claim 1, and a
polymer electrolyte.
4. The electrode catalyst layer for fuel cell according to claim 3,
wherein the electrolyte is a fluorine-based polymer
electrolyte.
5. A method for producing the electrode catalyst for fuel cell
according to claim 1, the method comprising: supporting a catalytic
metal containing platinum on a catalyst carrier precursor to obtain
a catalyst powder; and treating the catalyst powder with an
oxidative treatment solution to obtain a catalyst.
6. The method for producing the electrode catalyst for fuel cell
according to claim 5, wherein the catalyst carrier precursor has
the R' (D'/G intensity ratio) of 0.6 or less, which is the ratio of
D' band peak intensity (D' intensity) measured in the vicinity of
1620 cm.sup.-1 relative to G band peak intensity (G intensity)
measured in the vicinity of 1580 cm.sup.-1 by Raman
spectroscopy.
7. The method for producing the electrode catalyst for fuel cell
according to claim 5, wherein the BET specific surface area of the
catalyst carrier precursor is 900 m.sup.2/g or more.
8. A membrane electrode assembly for fuel cell comprising the
electrode catalyst for fuel cell set forth in claim 1.
9. A fuel cell comprising the membrane electrode assembly for fuel
cell set forth in claim 8.
Description
TECHNICAL FIELD
[0001] The present invention relates to an electrode catalyst for
fuel cell, method for producing the same, electrode catalyst layer
for fuel cell comprising the catalyst, and membrane electrode
assembly for fuel cell and fuel cell using the catalyst or the
catalyst layer.
BACKGROUND ART
[0002] A polymer electrolyte fuel cell (PEFC) using a
proton-conductive solid polymer membrane operates at lower
temperature compared to other types of a fuel cell such as a solid
oxide fuel cell or a molten carbonate fuel cell, for example. For
such reasons, the polymer electrolyte fuel cell is expected to be
used as a stationary power supply or a power source for a moving
object such as an automobile, and actual application thereof has
been already started.
[0003] For the polymer electrolyte fuel cell, an expensive metal
catalyst represented by Pt (platinum) or Pt alloy is generally
used. Furthermore, as a carrier for supporting the metal catalyst,
graphitized carbon is used from the viewpoint of water repellency
and corrosion resistance. It is described in JP 2005-26174 A to use
a carrier in which average lattice plant spacing of a [002] plane,
that is, d002, is 0.338 to 0.355 nm, specific surface area is 80 to
250 m.sup.2/g, and volume density is 0.30 to 0.45 g/ml. In JP
2005-26174 A, it is described that the durability of a cell is
improved by using the graphitized carbon.
SUMMARY OF INVENTION
[0004] However, although the catalyst using the carrier described
in JP 2005-26174 A has high durability, it has a problem that, as
an electrolyte is in contact with catalytic metal particles and a
transport path of the reaction gas (in particular, O.sub.2) to a
catalytic metal is blocked, the catalytic activity is lowered.
[0005] An object of the present invention is to provide an
electrode catalyst which has high durability and an excellent gas
transportability, an electrode catalyst layer, and a method for
producing the same.
[0006] Another object of the present invention is to provide an
electrode catalyst which has an excellent catalytic activity, an
electrode catalyst layer, and a method for producing the same.
[0007] Still another object of the present invention is to provide
a membrane electrode assembly and a fuel cell which have an
excellent power generation performance.
Means for Solving Problems
[0008] The inventors of the present invention conducted intensive
studies to solve the problems mentioned above. As a result, they
found that the problems can be solved if a catalyst with a specific
D'/G intensity ratio in which the ratio of a water vapor adsorption
amount compared to a nitrogen adsorption amount is within a
specific range is used. The present invention is completed
accordingly.
BRIEF DESCRIPTION OF DRAWING
[0009] FIG. 1 is a schematic cross-sectional view illustrating the
basic configuration of a polymer electrolyte fuel cell according to
an embodiment of the present invention. In FIG. 1, 1 denotes a
polymer electrolyte fuel cell (PEFC), 2 denotes a solid polymer
electrolyte membrane, 3 denotes a catalyst layer, 3a denotes an
anode catalyst layer, 3c denotes cathode catalyst layer, 4a denotes
an anode gas diffusion layer, 4c denotes a cathode gas diffusion
layer, 5 denotes a separator, 5a denotes an anode separator, 5c
denotes a cathode separator, 6a denotes an anode gas passage, 6c
denotes a cathode gas passage, 7 denotes a refrigerant passage, and
10 denotes a membrane electrode assembly (MEA).
[0010] FIG. 2 is a schematic explanatory cross-sectional view
illustrating the shape and structure of catalysts (a) and (c)
according to an embodiment of the present invention. In FIG. 2, 20
denotes a catalyst, 22 denotes a catalytic metal, 23 denotes a
carrier (catalyst carrier), 24 denotes a mesopore, and 25 denotes a
micropore.
[0011] FIG. 3 is a schematic explanatory cross-sectional view
illustrating the shape and structure of a catalyst (b) according to
an embodiment of the present invention. In FIG. 3, 20' denotes a
catalyst, 22' denotes a catalytic metal, 23' denotes carrier
(catalyst carrier) and 24' denotes a mesopore.
[0012] FIG. 4 is a graph illustrating the result of evaluation of
platinum coating on carriers B and C which was prepared in
Reference Examples 2 and 3 and carrier F which was prepared in
Reference Example 6 of Experiment 1.
DESCRIPTION OF EMBODIMENTS
[0013] An embodiment of the present invention is an electrode
catalyst for fuel cell containing a catalyst carrier having carbon
as a main component (it is also simply referred to as a "catalyst
carrier" or "carrier" in the present specification), and a
catalytic metal supported on the catalyst carrier, in which the
catalyst has the R' (D'/G intensity ratio) of 0.6 or less, which is
the ratio of D' band peak intensity (D' intensity) measured in the
vicinity of 1620 cm.sup.-1 relative to G band peak intensity (G
intensity) measured in the vicinity of 1580 cm.sup.-1 by Raman
spectroscopy, and the volume ratio of a water vapor adsorption
amount compared to a nitrogen adsorption amount at a relative
pressure of 0.5 in adsorption isotherm is 0.15 or more and 0.30 or
less.
[0014] Another embodiment of the present invention is an electrode
catalyst layer for fuel cell (in the present specification, it is
also simply referred to as a "catalyst carrier" or a "carrier")
including the catalyst for fuel cell of the above embodiment, and a
polymer electrolyte (it is also simply referred to as an
"electrolyte" in the present specification).
[0015] Namely, the catalyst of this embodiment satisfies the
following constitutions (I) and (II):
[0016] (I) The volume ratio of a water vapor adsorption amount
compared to a nitrogen adsorption amount is 0.15 or more and 0.30
or less.
[0017] (II) R' (D'/G intensity ratio), which is the ratio of D'
band peak intensity (D' intensity) measured in the vicinity of 1620
cm.sup.-1 relative to G band peak intensity (G intensity) measured
in the vicinity of 1580 cm.sup.-1 by Raman spectroscopy, is 0.6 or
less.
[0018] Meanwhile, as described herein, the G band measured in the
vicinity of 1580 cm-1 by Raman spectroscopy is also simply referred
to as "G band." As described herein, the D' band measured in the
vicinity of 1620 cm.sup.-1 by Raman spectroscopy is also simply
referred to as "D' band." Furthermore, each peak intensity of the G
band and D' band is also referred to as "G intensity" and "D'
intensity", respectively. Furthermore, the ratio of D' intensity
relative to G intensity is also simply referred to as "R' value" or
"D'/G intensity ratio."
[0019] Herein, the G band is a peak derived from graphite which is
measured in the vicinity of 1580 cm.sup.-1 (vibration inside
hexagonal lattice of a carbon atom) by Raman scattering analysis.
Furthermore, D' band is observed in the vicinity of 1620 cm.sup.-1
as a shoulder of G band by Raman scattering analysis. The D' band
is derived from a disorder or a defect of a graphite structure, and
it is present when the crystal size of graphite is small or many
edges are present on a graphene sheet. Unlike the center part of a
graphene molecule (6-membered ring), the electron state at edge
(end part) of a graphene molecule easily becomes a start point of
carbon corrosion. In other words, small R' value means that the
edge amount is small in carbon (graphene), which is a start point
of electrochemical corrosion as present in a graphite structure.
Accordingly, the durability can be improved by the above (II) so
that a decrease in catalytic activity can be effectively suppressed
and prevented.
[0020] Meanwhile, G band, D' band, and D band which is described
below, and their peak intensity are well known in the related
field. For example, reference can be made to R. Vidano and D. B
Fischbach, J. Am. Ceram. Soc. 61 (1978) 13-17 or G. Katagiri, H.
Ishida and A. Ishitani, Carbon 26 (1988) 565-571.
[0021] Meanwhile, when R' value is lowered by graphitization of
carbon for the purpose of improving durability, the catalyst
carrier turns out to have a hydrophobic property. As such, if a
polymer electrolyte having a hydrophobic structure in a main chain,
for example, fluorine-based polymer electrolyte or the like, is
used, the polymer electrolyte can easily adsorb onto a carrier on
which the catalytic metal is supported. Since the electrolyte can
more easily adsorb onto a surface of a catalytic metal compared to
gas such as oxygen, when such carrier is used, a surface of the
catalyst or an opening (entrance) of a pore is coated at high ratio
by an electrolyte. As a result, the gas transportability within a
catalyst layer is lowered, and thus a decrease in catalytic
activity and a decrease in power generation performance are
yielded. In order to obtain a sufficient power generation
performance, an expensive metal such as platinum needs to be used
in a large amount, and it leads to high production cost of a fuel
cell.
[0022] On the other hand, the catalyst of this embodiment satisfies
the above (I). The nitrogen adsorption amount is an indicator of a
specific surface area of a catalyst and the water vapor adsorption
amount is an indicator of a specific surface area with a
hydrophilic property of a catalyst. Thus, it can be said that the
higher ratio of a water vapor adsorption amount compared to a
nitrogen adsorption amount represents high hydrophillicity of a
catalyst. In this connection, since a contact between the catalytic
metal and electrolyte can be suppressed by controlling the
hydrophillicity of a catalyst, it is believed that the reaction gas
(in particular, O.sub.2) can be directly supplied without mediated
by an electrolyte to improve the gas transportability. The
inventors of the present invention found that, even when the
catalytic metal is not in contact with an electrolyte, the catalyst
can be effectively utilized according to forming of a three-phase
interface with water. For such reasons, as apart of the catalyst is
coated with an electrolyte (only a part of the electrolyte is in
contact with a catalytic metal), sites not requiring pass-through
of an electrolyte increase, and thus the gas transportability can
be improved. Accordingly, the reaction gas (in particular, O.sub.2)
can be transported more rapidly and also more efficiently to the
catalytic metal so that the catalyst can exhibit a high catalytic
activity, that is, the catalytic reaction can be promoted. This
effect can be also effectively exhibited under conditions with a
high load. Thus, a membrane electrode assembly and a fuel cell
having the catalyst of this embodiment or the catalyst layer
exhibit a high current and voltage (iV) property (voltage drop at
high current density is suppressed), and they have an excellent
power generation performance.
[0023] Meanwhile, the above mechanism is just an assumption, and
the present invention is not limited to such assumption.
[0024] Furthermore, the catalyst of this embodiment preferably
satisfies the following constitution (III);
[0025] (III) BET specific surface area is at least 900 m.sup.2/g
catalyst.
[0026] With the above (III), the catalyst can have a sufficient
specific surface area, and thus the electric double layer capacity
is high. As such, according to this catalyst, the dispersibility of
the catalyst is improved so that an area for electrochemical
reaction can be increased. In other words, the power generation
performance can be improved. Meanwhile, when the BET specific
surface area is 900 m.sup.2/g or more, the catalyst carrier has
many pores, in particular, mesopores that are described below.
Accordingly, as the entrance of the pores is clogged by a polymer
electrolyte, the gas transportability into the pores is impaired.
Since the catalytic metal is supported in the pores, when the gas
transportability into the pores is impaired, the catalytic activity
is lowered. Meanwhile, according to this embodiment, the coating
rate of a polymer electrolyte by a catalyst is low due to the above
(I) so that clogging of pore entrance by a polymer electrolyte can
be suppressed, and thus efficient transport of gas into pores can
be achieved.
[0027] According to the above embodiment, a transport path of gas
is ensured by controlling the amount of a catalytic metal in a
suitable range to which reaction gas can reach without passing
through an electrolyte. As such, the electrode catalyst layer can
have an improved gas transportability, and also an excellent
catalytic activity. Furthermore, according to the present
invention, as the catalyst has low R' value, the electrode catalyst
layer has high durability so that a high catalytic activity is
maintained.
[0028] Thus, by having an improved gas transportability, the fuel
cell catalyst for fuel cell of this embodiment, and the catalyst
layer for fuel cell using this can exhibit a high catalytic
activity, and also can maintain the activity. In addition, a
membrane electrode assembly and a fuel cell having this catalyst or
this catalyst layer have excellent power generation performance and
durability. As such, another embodiment of the present invention is
a fuel cell membrane electrode assembly which includes the
aforementioned fuel cell electrode catalyst or fuel cell electrode
catalyst layer. Still another embodiment of the present invention
is a fuel cell which includes the fuel cell membrane electrode
assembly.
[0029] Hereinbelow, one embodiment of the catalyst of the present
invention and one embodiment of a catalyst layer, a membrane
electrode assembly (MEA), and a fuel cell using the catalyst are
described in detail with suitable reference to the drawings.
However, the present invention is not limited to the following
embodiments. Meanwhile, each drawing is exaggerated for the
convenience of description, and the dimensional ratio of each
constitutional element can be different from actual ratios.
Furthermore, when descriptions of the embodiment of the present
invention are given in view of the drawings, the same elements are
given with the same symbols for describing the drawings, and
overlapped descriptions are omitted.
[0030] Furthermore, as described herein, "X to Y" for representing
a range means "X or more and Y or less." Furthermore, unless
specifically described otherwise, operations and measurements of
physical properties or the like are performed at room temperature
(20 to 25.degree. C.)/relative humidity of 40 to 50%.
[0031] [Fuel Cell]
[0032] A fuel cell has a membrane electrode assembly (MEA) and a
pair of separator having an anode-side separator having a fuel gas
passage for flowing fuel and a cathode-side separator having an
oxidant gas passage for flowing an oxidant. The fuel cell according
to this embodiment has excellent durability and it can exhibit very
high power generation performance.
[0033] FIG. 1 is a schematic cross-sectional view illustrating the
basic configuration of a polymer electrolyte fuel cell (PEFC) 1
according to an embodiment of the present invention. PEFC 1 has a
solid polymer electrolyte membrane 2, and a pair of catalyst layers
(anode catalyst layer 3a and cathode catalyst layer 3c) to sandwich
the solid polymer electrolyte membrane 2. A laminated body
constituted by the solid polymer electrolyte membrane 2 and the
catalyst layers (3a and 3c) is sandwiched by a pair of gas
diffusion layers (GDL) (anode gas diffusion layer 4a and cathode
gas diffusion layer 4c). Thus, the solid polymer electrolyte
membrane 2, the pair of the catalyst layers (3a and 3c) and the
pair of the gas diffusion layers (4a and 4c) are stacked to
constitute a membrane electrode assembly (MEA) 10.
[0034] In the PEFC 1, the MEA 10 is further sandwiched by a pair of
separators (anode separator 5a and cathode separator 5c). In FIG.
1, the separators (5a and 5c) are shown as being located on both
ends of the illustrated MEA 10. However, in a fuel cell stack in
which a plurality of MEAs is stacked up, the separators are also
generally used as the separators for the adjacent PEFC (not shown).
In other words, the MEAs form a stack by sequentially laminated via
the separators in a fuel cell stack. In other words, a fuel cell
stack is constituted in such a manner that the MEAs are
sequentially stacked via a separator to form a stack. Meanwhile, in
an actual fuel cell stack, gas seal members are provided between
the separator (5a and 5c) and the solid polymer electrolyte
membrane 2, or between the PEFC 1 and the adjacent other PEFC.
However, they are not illustrated in FIG. 1.
[0035] The separators (5a and 5c) are obtained by, for example,
applying a press forming process to thin plates with a thickness of
0.5 mm or less, forming a corrugating shape as shown in FIG. 1. The
convex areas of the separators (5a and 5c) seen from the MEA side
are in contact with the MEA 10. Therefore, an electrical connection
with the MEA 10 is surely obtained. Furthermore, the concave areas
as viewed from the MEA of the separator (5a and 5c) (spaces between
the separator and the MEA derived from the concave-convex shape of
the separator) function as a gas passage through which gas flows at
the time of the operation of the PEFC 1. Specifically, a fuel gas
(for example, hydrogen or the like) flows in gas passage 6a of the
anode separator 5a, and an oxidant gas (for example, air or the
like) flows in gas passages 6c of the cathode separator 5c.
[0036] Meanwhile, the concave areas as viewed from the opposite
side of the MEA of the separator (5a and 5c) become a refrigerant
passage 7 through which a refrigerant (for example, water) flows to
cool the PEFC at the time of the operation of the PEFC 1.
Furthermore, the separator is generally provided with a manifold
(not shown). The manifold functions as a connection means for
connecting each cell when constituting a stack. By having such a
constitution, mechanical strength of the fuel cell stack can be
obtained.
[0037] Meanwhile, according to the embodiment illustrated in FIG.
1, the separator (5a and 5c) is formed to have a concave-convex
shape. However, the separator is not limited to have such
concave-convex shape, and as long as it can exhibit the function as
a gas passage and a refrigerant passage, it can have any shape such
as flat shape or a partial concave-convex shape.
[0038] The fuel cell having MEA of the present invention as
described above exhibits an excellent power generation performance
and excellent durability. Herein, a type of the fuel cell is not
particularly limited. Although descriptions are given above by
having a polymer electrolyte fuel cell as an example, other
examples include an alkali fuel cell, a direct methanol fuel cell,
and a micro fuel cell. Among them, as having a small size and high
density and high output, a polymer electrolyte fuel cell (PEFC) can
be preferably mentioned. Furthermore, the aforementioned fuel cell
is also useful as a stationary power supply in addition to a power
source for a moving object such as an automobile which has limited
loading space. It is particularly preferably used as a power source
for a moving object such as an automobile where high output voltage
is required after stopping operation for a relatively long
time.
[0039] A type of fuel gas used at the time of the operation of the
fuel cell is not particularly limited. Examples of the fuel gas
include hydrogen, methanol, ethanol, 1-propanol, 2-propanol,
1-butanol, secondary butanol, tertiary butanol, dimethyl ether,
diethyl ether, ethylene glycol and diethylene glycol. Particularly,
hydrogen and methanol are preferably used in terms of having a high
output property.
[0040] Furthermore, the use for which the fuel cell can be applied
is not particularly limited, but it is suitably applied to a motor
vehicle. The electrolyte membrane-electrode assembly of the present
invention has an excellent power generation performance and
excellent durability and it allows obtainment of a cell with small
size. For such reasons, the fuel cell of the present invention is
particularly advantageous when it is applied to a motor vehicle
from the viewpoint of installing it on a vehicle. Accordingly, the
present invention provides a motor vehicle having the fuel cell of
the present invention.
[0041] Hereinbelow, the members constituting the fuel cell of the
present invention are briefly described, but the technical scope of
the present invention is not limited to the following
embodiments.
[0042] [Electrode Catalyst Layer (Catalyst Layer)]
[0043] The electrode catalyst layer (catalyst layer) of the present
embodiment may be either a cathode catalyst layer or an anode
catalyst layer, but is preferably a cathode catalyst layer. As
described above, in the catalyst layer of the present embodiment, a
catalyst can be effectively used by forming three-phase interfaces
with water even when the catalyst and the electrolyte are not in
contact with each other, because water is formed in the cathode
catalyst layer.
[0044] As described herein, the catalyst layer essentially contains
a catalyst, in which a catalytic metal is supported on the catalyst
carrier, and an electrolyte.
[0045] (Catalyst)
[0046] (II) R' (D'/G intensity ratio) which is a ratio of D'
intensity relative to G intensity of the catalyst is 0.6 or
less.
[0047] According to the above (II), the amount of the edge of
carbon (graphene) which becomes a start point of electrochemical
corrosion in the graphite structure of the catalyst carrier can be
kept at sufficiently low level. Accordingly, the durability can be
improved and a reduction in the catalytic activity when supported
with a catalytic metal can be effectively suppressed and prevented.
From the viewpoint of further improvement of durability, the R'
value (D'/G intensity ratio) of the catalyst is preferably 0 to
0.6, and more preferably 0 to 0.51.
[0048] In addition to above, the catalyst preferably has (II') R
(D/G intensity ratio) of 1.7 or more, which is a ratio of D
intensity relative to G intensity. Meanwhile, the D band measured
around 1360 cm-1 by Raman spectroscopy is also herein simply
referred to as "D band". Furthermore, peak intensity of D band is
also referred to as "D intensity." Furthermore, the ratio of the D
intensity relative to the G intensity is simply referred to as "R
value" or "D/G intensity ratio." Herein, D band is observed around
1360 cm-1 by Raman scattering analysis, and it results from a
disorder or a defect in a graphite structure. It appears when
orientation property of graphene molecule is high or graphitization
level is high. In other words, a high R value means low
graphitization level of carbon powder (carrier). For such reasons,
when R value is 1.7 or more, electric double layer capacity per
surface area of carbon powder becomes larger, and thus the
catalytic activity can be more effectively improved. Considering a
further improvement of the electric double layer capacity
(catalytic activity), the R value (D/G intensity ratio) of a
catalyst is preferably more than 1.75 and 2.5 or less, and more
preferably 1.8 to 2.4.
[0049] Meanwhile, in the present specification, the R' value is
obtained by measuring Raman spectrum of a catalyst (or a catalyst
carrier precursor which will be described later) by using a micro
Raman spectrometer and calculating the relative intensity ratio
between the peak intensity around 1620 cm.sup.-1 (D' intensity)
referred to as a D' band and the peak intensity around 1580
cm.sup.-1 (G intensity) referred to as a G band, that is, the peak
area ratio of (D' intensity/G intensity). Similarly, the R value is
obtained by measuring Raman spectrum of a catalyst (or a catalyst
carrier precursor which will be described later) by using a micro
Raman spectrometer and calculating the relative intensity ratio
between the peak intensity around 1360 cm.sup.-1 (D intensity)
referred to as a D band and the peak intensity around 1580
cm.sup.-1 (G intensity) referred to as a G band, that is, the peak
area ratio of (D intensity/G intensity). As for the peak area, the
area obtained by Raman spectrometric measurement which is described
below is used.
[0050] (Raman Spectrometry Measurement)
[0051] The Raman spectrum was measured using a microlaser Raman
[0052] SENTERRA (manufactured by Bruker Optics K.K.) as a measuring
apparatus, at room temperature (25.degree. C.), exposure of 30
seconds.times.integration of 4 times, in the following conditions.
Meanwhile, the peaks of G band, D' band and D band can be
determined by peak fitting based on Gaussian distribution.
[0053] [Formula 1]
<Measurement Conditions>
[0054] Excitation wavelength: SHG of Nd:YAG, 532 nm Laser output: 3
mW Spot size: .about.1 .mu.m
Detector: CCD
[0055] As for the catalyst, the volume ratio of a water vapor
adsorption amount compared to a nitrogen adsorption amount at
relative pressure (P/P0) of 0.5 in adsorption isotherm
(hereinbelow, also referred to as water vapor adsorption
amount/nitrogen adsorption amount) is 0.15 or more and 0.30 or
less. Preferably, the water vapor adsorption amount/nitrogen
adsorption amount is 0.18 or more and 0.25 or less. As the water
vapor adsorption amount/nitrogen adsorption amount is 0.15 or more,
the catalyst becomes hydrophilic so that it becomes difficult to
have adsorption with a hydrophobic moiety of a polymer electrolyte.
Furthermore, as the water vapor adsorption amount/nitrogen
adsorption amount is 0.30 or less, the adsorption by a hydrophilic
group of a polymer electrolyte can be suppressed. Namely, when the
water vapor adsorption amount/nitrogen adsorption amount is 0.15 or
more and 0.30 or less, a good balance between hydrophillicity and
hydrophobicity in the catalyst is obtained even when R' value is
0.6 or less, and thus the electrolyte partially coats the catalytic
metal (only part of the electrolyte is in contact with the
catalytic metal). Accordingly, sites not requiring pass-through of
an electrolyte increase, and thus the gas transportability can be
improved.
[0056] Herein, defining of the water vapor adsorption
amount/nitrogen adsorption amount is made by replacing the whole
surface area of particles with the nitrogen adsorption and
replacing the hydrophilic surface area with the water vapor
adsorption for a state in which gas (nitrogen and water vapor) is
adsorbed as a single layer on a particle surface. When P/P0>0.5,
a multilayer adsorption of gas molecules is initiated so that it is
inappropriate to have the gas adsorption amount as an indicator of
a surface area. On the other hand, for a region in which P/P0 is
significantly lower than 0.5, the gas molecules adsorb not onto
every particle surface. For such reasons, the water vapor
adsorption amount/nitrogen adsorption amount is defined at
P/P0=0.5.
[0057] The nitrogen adsorption amount indicates a nitrogen
adsorption amount (cm.sup.3/g) at relative pressure (P/P0) of 0.5
in adsorption isotherm, which is measured at the conditions
described in the following Table 1.
[0058] The nitrogen adsorption isotherm is measured by carefully
weighing about 0.02 to 0.04 g of the catalyst powder, adding it in
a sample tube followed by sealing, and dried preliminary at the
temperature and time for pre-treatment described in the following
Table 1 to give a measurement sample. The measurement is then
carried out according to the following measurement conditions. For
the weighting, an electronic balance (AW220) manufactured by
Shimadzu Corporation is used.
TABLE-US-00001 TABLE 1 Measurement instrument manufactured by BEL
Japan, Inc. Adsorbent N.sub.2 Dead volume measurement gas He
Measurement temperature 77K (liquid nitrogen temperature) Saturated
vapor pressure P.sub.0 Atmospheric pressure Incubator pipe
temperature 35.degree. C. Measurement mode P/P.sub.0 Isothermal
adsorption process and desorption process Measurement relative
pressure About 0 to 1 Setting time for equilibration 180 s compared
to 1 relative pressure (180 s after reaching the equilibrium
pressure) Temperature time for pre-treatment Deaeration under
reduced pressure at 90.degree. C. .times. about 5 hours Sample
amount About 0.02 to 0.04 g
[0059] Furthermore, the water vapor adsorption amount indicates a
water vapor adsorption amount (cm.sup.3/g) at relative pressure
(P/P0) of 0.5 in adsorption isotherm, which is measured at the
conditions described in the following Table 2.
[0060] The water vapor adsorption isotherm is measured by carefully
weighing 0.0461 g of the catalyst powder, adding it in a sample
tube followed by sealing, and dried preliminary at the temperature
and time for pre-treatment described in the following Table 2 to
give a measurement sample. The measurement is then carried out
according to the following measurement conditions. For the
weighting, an electronic balance (AW220) manufactured by Shimadzu
Corporation is used.
TABLE-US-00002 TABLE 2 Measurement instrument manufactured by BEL
Japan, Inc. Adsorbent H.sub.2O (molecular weight: 18) Dead volume
measurement gas He Measurement temperature 80.degree. C. Saturated
vapor pressure P.sub.0 47.416 kPa (at 80.degree. C. ) Incubator
pipe temperature 100.degree. C. Measurement mode Isothermal
adsorption process and desorption process Measurement relative
pressure P/P.sub.0 About 0 to 1 Setting time for equilibration 500
s compared to 1 relative pressure (measured for 500 s after
reaching the equilibrium pressure) Temperature time for
pre-treatment Deaeration under reduced pressure at 90.degree. C.
.times. about 5 hours Sample amount 0.0461 g
[0061] With regard to the catalyst, it is preferable that an acidic
group is present on a surface of the catalyst particle or on a
surface of pores and the amount of the acidic group per weight of a
carrier is preferably 0.7 mmol/g carrier or more. The acidic group
is not particularly limited, it if is a functional group which can
release protons upon dissociation. However, it preferably contains
at least one selected from a group consisting of a hydroxyl group,
a lactone group, and a carboxy group. When the carrier contains
carbon, the acidic group preferably contains a hydroxyl group, a
lactone group, or a carboxy group. When the carrier contains metal
oxide, the acidic group preferably contains a hydroxyl group. Those
acidic groups are a hydrophilic group, and even when a catalyst
with R' value of 0.6 or less is used, a catalyst surface with
hydrophilic-like property can be provided and adsorption of an
electrolyte on a catalytic metal can be obtained at an appropriate
level.
[0062] The amount of the acidic group is preferably more than 0.75
mmol/g carrier, more preferably 1.2 mmol/g carrier or more, and
even more preferably 1.8 mmol/g carrier or more. Meanwhile, the
upper limit of the amount of the acidic group is, although not
particularly limited, preferably 3.0 mmol/g carrier or less, and
more preferably 2.5 mmol/g carrier or less from the viewpoint of
carbon durability.
[0063] The amount of the acidic group can be measured by a
titration method using an alkali compound. Specifically, it can be
measured by the following method.
[Measurement of Amount of Acidic Group]
[0064] First, 2.5 g of catalyst powder having an acidic group is
washed with 1 liter of hot pure water followed by drying. After the
drying, it was weighed such that the carbon amount contained in the
catalyst having an acidic group is 0.25 g, and after stirring with
55 ml of water for 10 minutes, it was subjected to ultrasonic
dispersion for 2 minutes. Next, the catalyst dispersion is
transferred to a glove box purged with nitrogen gas, and bubbled
with nitrogen gas for 10 minutes. And, to the catalyst dispersion,
0.1 M aqueous base solution is added in an excess amount, and by
performing neutralization treatment of this basic solution with 0.1
M hydrochloric acid, the amount of functional group is quantified
based on the neutralization point. Herein, as an aqueous base
solution, three kinds including NaOH, Na.sub.2CO.sub.3, and
NaHCO.sub.3 were used, and the neutralization titration operation
is performed for each, because the type of the functional group to
be neutralized is different for each base used. In the case of
NaOH, the neutralization reaction occurs with a carboxy group, a
lactone group, and a hydroxyl group. In the case of
Na.sub.2CO.sub.3, the neutralization reaction occurs with a carboxy
group and a lactone group. In the case of NaHCO.sub.3, the
neutralization reaction occurs with a carboxy group. Based on the
type and amount of the base for three kinds of a base added for
titration and the resulting amount of consumed hydrochloric acid,
the amount of an acidic group is calculated. Meanwhile, for
determination of a neutralization point, a pH meter is used. In the
case of NaOH, the neutralization point is pH 7.0. In the case of
Na.sub.2CO.sub.3, it is pH 8.5. In the case of NaHCO.sub.3, it is
pH 4.5. Accordingly, the total amount of a carboxy group, a lactone
group, and a hydroxyl group that are added to the catalyst is
obtained.
[0065] The catalyst (after supporting of catalytic metal)
preferably has (III) BET specific surface area of at least 900
m.sup.2/g carrier. More preferably, it is 1000 m.sup.2/g catalyst
or more, even more preferably 1000 to 3000 m.sup.2/g catalyst, and
particularly preferably 1100 to 1800 m.sup.2/g catalyst. With this
specific surface area, the catalyst has a sufficient specific
surface area so that large electric double layer capacity can be
achieved.
[0066] In the case of the specific surface area as described above,
sufficient mesopores and micropores that are described below can be
secured, thus while securing micropores (lower gas transport
resistance) sufficient for gas transport, more catalytic metal can
be stored (carried) in the mesopores. Also, the electrolyte and the
catalytic metal in the catalyst layer can be physically separated
(contact between the electrolyte and the catalytic metal can be
more effectively suppressed and prevented). Therefore, the activity
of the catalytic metal can be more effectively utilized. In
addition, as the micropores function as a transport path of gas, a
three-phase interface with water is more significantly formed so
that and the catalytic reaction can be more effectively
promoted.
[0067] According to this embodiment, part of the catalyst is coated
with an electrolyte so that clogging by the electrolyte of an
entrance of a mesopore in which a catalytic metal is supported can
be suppressed, and thus efficient transport of gas to the catalytic
metal can be achieved.
[0068] Meanwhile, the "BET specific surface area (m.sup.2/g
catalyst)" in the present specification is measured by the nitrogen
adsorption method. In detail, about 0.04 to 0.07 g of sample
(carbon powder, catalyst powder) is accurately weighed, and sealed
in a test tube. The test tube is preliminarily dried in a vacuum
dryer at 90.degree. C. for several hours to obtain a measurement
sample. An electronic balance (AW220) manufactured by Shimadzu
Corporation is used for weighing. Meanwhile, as for the coated
sheet, about 0.03 to 0.04 g of the net weight of a coating layer in
which the weight of Teflon (registered trademark) (substrate) of
the same area is deducted from the total weight of the coated sheet
is used as a sample weight. Next, the BET specific surface area is
measured at the following measurement conditions. A BET plot is
obtained from a relative pressure (P/P0) range of about 0.00 to
0.45, in the adsorption side of the adsorption and desorption
isotherms, thereby calculating the BET specific surface area from
the slope and intercept thereof.
[0069] [Formula 2]
<Measurement Conditions>
[0070] Measurement instrument: High accuracy all-automated gas
adsorption instrument manufactured by BEL Japan, Inc. BELSORP
36
Adsorption gas: N.sub.2
[0071] Dead volume measurement gas: He Adsorption temperature: 77 K
(temperature of liquid nitrogen) Pre-measurement treatment: vacuum
dry at 90.degree. C. for several hours (set on the measurement
stage after purging with He) Measurement mode: isothermal
adsorption process and desorption process Measurement relative
pressure P/P.sub.0: about 0 to 0.99 Setting time for equilibration:
180 seconds for every relative pressure
[0072] The catalyst preferably satisfies one of the following (a)
to (c):
[0073] (a) the catalyst has pores with a radius of less than 1 nm
and pores with a radius of 1 nm or more, a pore volume in the pores
with a radius of less than 1 nm is 0.3 cc/g carrier or more, and
the catalytic metal is supported inside the pores with a radius of
1 nm or more;
[0074] (b) the catalyst has pores with a radius of 1 nm or more and
less than 5 nm, a pore volume of the pores is 0.8 cc/g carrier or
more, and the catalytic metal has a specific surface area of 60
m.sup.2/g carrier or less; and
[0075] (c) the catalyst has pores with a radius of less than 1 nm
and pores with a radius of 1 nm or more, a mode radius of pore
distribution in the pores with a radius of less than 1 nm is 0.3 nm
or more and less than 1 nm, and the catalytic metal is supported
inside the pores with a radius of 1 nm or more. Meanwhile, in the
present specification, the catalyst satisfying the above (a) is
also referred to as the "catalyst (a)", the catalyst satisfying the
above (b) is also referred to as the "catalyst (b)", and the
catalyst satisfying the above (c) is also referred to as the
"catalyst (c)".
[0076] Instead of the above, or in addition to the above, the
catalyst preferably satisfies the following (d):
[0077] (d) the catalyst has a mode radius of pores with a radius of
1 nm or more of pore distribution of 1 nm or more and less than 5
nm, the catalytic metal is supported inside the pores with a radius
of 1 nm or more, the mode radius is the same or less than the
average particle radius of the catalytic metal, and a pore volume
in the pores with a radius of 1 nm or more and less than 5 nm is
0.4 cc/g carrier or more.
[0078] Meanwhile, in the present specification, the catalyst
satisfying the above (d) is also referred to as the "catalyst
(d)".
[0079] Hereinbelow, the catalyst (a) to (d) are described in detail
as preferred modes.
[0080] (Catalysts (a) and (c))
[0081] The catalyst (a) contains a catalyst carrier and a catalytic
metal supported on the catalyst carrier and satisfies the following
constitutions (a-1) to (a-3):
[0082] (a-1) the catalyst has pores with a radius of less than 1 nm
(primary pores) and pores with a radius of 1 nm or more (primary
pores);
[0083] (a-2) a pore volume of the pores with a radius of less than
1 nm is 0.3 cc/g carrier or more; and
[0084] (a-3) the catalytic metal is supported inside the pores with
a radius of 1 nm or more.
[0085] In addition, the catalyst (c) contains a catalyst carrier
and a catalytic metal supported on the catalyst carrier and
satisfies the following constitutions (a-1), (c-1) and (a-3):
[0086] (a-1) the catalyst has pores with a radius of less than 1 nm
and pores with a radius of 1 nm or more;
[0087] (c-1) a mode radius of pore distribution in the pores with a
radius of less than 1 nm have is 0.3 nm or more and less than 1 nm;
and
[0088] (a-3) the catalytic metal is supported inside the pores with
a radius of 1 nm or more.
[0089] Meanwhile, in the present specification, the pores with a
radius of less than 1 nm are also referred to as a "micropore." In
addition, in the present specification, the pores with a radius 1
nm or more are also referred to as a "mesopore."
[0090] As described above, the inventors of the present invention
have found that, even when a catalytic metal does not contact an
electrolyte, the catalytic metal can be effectively used by forming
three-phase interfaces with water. Therefore, in the catalysts (a)
and (c), by adopting a constitution that the (a-3) the catalytic
metal is supported inside the mesopores in which the electrolyte
cannot enter, and thus the catalytic activity can be improved.
Meanwhile, when the catalytic metal is supported inside the
mesopores in which the electrolyte cannot enter, the transport
distance of gas such as oxygen is increased, and gas
transportability is lowered, thus a sufficient catalytic activity
cannot be elicited, and catalytic performance is deteriorated under
high load conditions. On the other hand, if the (a-2) the pore
volume of micropores in which the electrolyte and the catalytic
metal may not or cannot enter at all is sufficiently secured, or
the (c-1) the mode radius of the micropores is set large, the
transport path of gas can be sufficiently secured. Therefore, gas
such as oxygen can be efficiently transported to the catalytic
metal in the mesopores, namely, gas transport resistance can be
reduced. According to this constitution, gas (for example, oxygen)
passes through micropores (gas transportability is improved), and
gas can be efficiently contacted with the catalytic metal.
Therefore, when the catalysts (a) and (c) are used in the catalyst
layer, micropores are present in large volume, thus a reaction gas
can be transported to the surface of the catalytic metal present in
the mesopores via the micropores (path), and gas transport
resistance can be further reduced. Therefore, the catalyst layer
containing the catalysts (a) and (c) can exhibit higher catalytic
activity, namely, the catalytic reaction can be further promoted.
Therefore, the membrane electrode assembly and the fuel cell having
the catalyst layer containing the catalysts (a) and (c) can further
increase power generation performance.
[0091] FIG. 2 is a schematic explanatory cross-sectional view
illustrating the shape and structure of the catalysts (a) and (c).
As illustrated in FIG. 2, the catalysts (a) and (c) illustrated by
20 consist of a catalytic metal 22 and a catalyst carrier 23. Also,
a catalyst 20 has pores 25 with a radius of less than 1 nm
(micropores) and pores 24 with a radius of 1 nm or more
(mesopores). The catalytic metal 22 is supported inside the
mesopores 24. Also, it is enough that at least a part of the
catalytic metal 22 is supported inside the mesopores 24, and a part
may be supported on the surface of the catalyst carrier 23.
However, it is preferable that substantially all of the catalytic
metal 22 is supported inside the mesopores 24, from the viewpoint
of preventing the contact between the electrolyte and the catalytic
metal in the catalyst layer. The phrase "substantially all of the
catalytic metal" is not particularly limited so long as it is the
amount that can sufficiently improve the catalytic activity. The
phrase "substantially all of the catalytic metal" is present in an
amount of preferably 50% by weight or more (upper limit: 100% by
weight) and more preferably 80% by weight or more (upper limit:
100% by weight), in the whole catalytic metal.
[0092] The phrase "the catalytic metal is supported inside the
mesopores" herein can be confirmed by reduction in the volume of
mesopores before and after supporting the catalytic metal on the
catalyst carrier precursor. In detail, the catalyst carrier
precursor has micropores and mesopores, and each pore has a certain
volume, but when the catalytic metal is supported in these pores,
the volume of each pore is reduced. Therefore, when the difference
between the volume of mesopores of the catalyst carrier precursor
before supporting the catalytic metal and the volume of mesopores
of the catalyst powder after supporting the catalytic metal
[=(volume before supporting)-(volume after supporting)] exceeds 0,
it means that "the catalytic metal is supported inside the
mesopores". Similarly, when the difference between the volume of
micropores of the catalyst carrier precursor before supporting the
catalytic metal and the volume of micropores of the catalyst powder
after supporting the catalytic metal [=(volume before
supporting)-(volume after supporting)] exceeds 0, it means that
"the catalytic metal is supported inside the micropores".
Preferably, the catalytic metal is supported in the mesopores more
than in the micropores (reduction value of the volume of mesopores
between before and after supporting>reduction value of the
volume of micropores between before and after supporting). It is
because gas transport resistance is reduced, and thus a path for
gas transport can be sufficiently secured. The reduction value of
the pore volume of mesopores between before and after supporting
the catalytic metal is preferably 0.02 cc/g or more, and more
preferably 0.02 to 0.4 cc/g, in consideration of the reduction in
gas transport resistance, securing of the path for gas transport,
and the like.
[0093] In addition, it is preferable that the pore volume of pores
with a radius of less than 1 nm (micropores) (of the catalyst after
supporting the catalytic metal) is 0.3 cc/g carrier or more, and/or
the mode radius (modal radius) of pore distribution of micropores
(of the catalyst after supporting the catalytic metal) is 0.3 nm or
more and less than 1 nm. More preferably, the pore volume of
micropores is 0.3 cc/g carrier or more, and the mode radius of pore
distribution of micropore is 0.3 nm or more and less than 1 nm.
When the pore volume and/or mode radius of micropores is within the
above range, micropores sufficient for gas transport can be
secured, and gas transport resistance is small. Therefore, a
sufficient amount of gas can be transported to the surface of the
catalytic metal present in the mesopores via the micropores (path),
thus a high catalytic activity can be exhibited, namely, the
catalytic reaction can be promoted. Also, electrolyte (ionomer) and
liquid (for example, water) cannot enter the micropores, only gas
is selectively passed (gas transport resistance can be reduced).
The pore volume of micropores is more preferably 0.3 to 2 cc/g
carrier, and particularly preferably 0.4 to 1.5 cc/g carrier, in
consideration of the effect of improving gas transportability. In
addition, the mode radius of pore distribution of micropores is
more preferably 0.4 to 1 nm, and particularly preferably 0.4 to 0.8
nm. The pore volume of pores with a radius of less than 1 nm is
herein also simply referred to as "the pore volume of micropores".
Similarly, the mode radius of pore distribution of micropores is
herein also simply referred to as "the mode radius of
micropores".
[0094] The pore volume of the pores with a radius of 1 nm or more
and less than 5 nm (mesopores) in catalyst (a) or (c) is not
particularly limited, but is preferably 0.4 cc/g carrier or more,
more preferably 0.4 to 3 cc/g carrier, and particularly preferably
0.4 to 1.5 cc/g carrier. When the pore volume is within the above
range, more catalytic metal can be stored (supported) in the
mesopores, and the electrolyte and the catalytic metal in the
catalyst layer can be physically separated (contact between the
catalytic metal and the electrolyte can be more effectively
suppressed and prevented). Therefore, the activity of the catalytic
metal can be more effectively utilized. Also, by the presence of
many mesopores, the catalytic reaction can be more effectively
promoted. In addition, the micropores act as a transport path of
gas, and three-phase interfaces are more remarkably formed by
water, thus the catalytic activity can be further improved. The
pore volume of pores with a radius of 1 nm or more and less than 5
nm is herein also simply referred to as "the pore volume of
mesopores".
[0095] The mode radius (modal radius) of pore distribution of pores
with a radius of 1 nm or more (mesopores) in catalyst (a) or (c) is
not particularly limited, but is preferably 1 to 5 nm, more
preferably 1 to 4 nm, and particularly preferably 1 to 3 nm. In the
case of the mode radius of pore distribution of mesopores described
above, a more sufficient amount of the catalytic metal can be
stored (supported) in the mesopores, and the electrolyte and the
catalytic metal in the catalyst layer can be physically separated
(contact between the catalytic metal and the electrolyte can be
more effectively suppressed and prevented). Therefore, the activity
of the catalytic metal can be more effectively utilized. Also, by
the presence of large-volume mesopores, the catalytic reaction can
be more effectively promoted. In addition, the micropores act as a
transport path of gas, and three-phase interfaces are more
remarkably formed by water, thus the catalytic activity can be
further improved. The mode radius of pore distribution of mesopores
is herein also simply referred to as "the mode radius of
mesopores".
[0096] The "radius of pores of micropores (nm)" in the present
specification refers to a radius of pores measured by the nitrogen
adsorption method (MP method). Also, the "mode radius of pore
distribution of micropores (nm)" herein refers to a pore radius at
a point taking a peak value (maximum frequency) in the differential
pore distribution curve that is obtained by the nitrogen adsorption
method (MP method). The lower limit of the pore radius of
micropores is the lower limit that can be measured by the nitrogen
adsorption method, that is, 0.42 nm or more. Similarly, the "radius
of pores of mesopores (nm)" refers to a radius of pores measured by
the nitrogen adsorption method (DH method). Also, the "mode radius
of pore distribution of mesopores (nm)" refers to a pore radius at
a point taking a peak value (maximum frequency) in the differential
pore distribution curve that is obtained by the nitrogen adsorption
method (DH method). Herein, the upper limit of the pore radius of
mesopores is not particularly limited, but is 5 nm or less.
[0097] The "pore volume of micropores" in the present specification
refers to a total volume of micropores with a radius of less than 1
nm present in the catalyst, and expressed as a volume per 1 g of
the carrier (cc/g carrier). The "pore volume of micropores (cc/g
carrier)" is calculated as a downside area (integrated value) under
the differential pore distribution curve obtained by the nitrogen
adsorption method (MP method). Similarly, the "pore volume of
mesopores" refers to a total volume of mesopores with a radius of 1
nm or more and less than 5 nm present in the catalyst, and
expressed as a volume per 1 g of the carrier (cc/g carrier). The
"pore volume of mesopores (cc/g carrier)" is calculated as a
downside area (integrated value) under the differential pore
distribution curve obtained by the nitrogen adsorption method (DH
method).
[0098] The "differential pore distribution" in the present
specification refers to a distribution curve obtained by plotting a
pore size on the horizontal axis and a pore volume corresponding to
the pore size in the catalyst on the vertical axis. That is to say,
in the case of regarding the pore volume of the catalyst obtained
by the nitrogen adsorption method (MP method in the case of
micropores; DH method in the case of mesopores) as V and the pore
diameter as D, a value (dV/d (log D)) obtained by dividing that
differential pore volume dV by logarithmic difference of the pore
diameter d (log D) is determined. Moreover, the differential pore
distribution curve is obtained by plotting this dV/d (log D) to the
average pore diameter of each section. The differential pore volume
dV indicates the increment of the pore volume between measuring
points.
[0099] The method for measuring the radius of micropores and pore
volume by the nitrogen adsorption method (MP method) is not
particularly limited, and for example, the method described in
known documents such as "Science of Adsorption" (second edition,
written jointly by Seiichi Kondo, Tatsuo Ishikawa and Ikuo Abe,
MARUZEN Co., Ltd.), "Fuel Cell Characterization Methods" (edited by
Yoshio Takasu, Masaru Yoshitake, Tatsumi Ishihara, Kagaku-Dojin
Publishing Co., Inc.), and R. Sh. Mikhail, S. Brunauer, E. E. Bodor
J. Colloid Interface Sci., 26, 45 (1968) can be used. The radius of
micropores and pore volume by the nitrogen adsorption method (MP
method) are a value herein measured by the method described in R.
Sh. Mikhail, S. Brunauer, E. E. Bodor J. Colloid Interface Sci.,
26, 45 (1968).
[0100] The method for measuring the radius of mesopores and pore
volume by the nitrogen adsorption method (DH method) is not also
particularly limited, and for example, the method described in
known documents such as "Science of Adsorption" (second edition,
written jointly by Seiichi Kondo, Tatsuo Ishikawa and Ikuo Abe,
MARUZEN Co., Ltd.), "Fuel Cell Characterization Methods" (edited by
Yoshio Takasu, Masaru Yoshitake, Tatsumi Ishihara, Kagaku-Dojin
Publishing Co., Inc.), and D. Dollion, G. R. Heal: J. Appl. Chem.,
14, 109 (1964) can be used. The radius of mesopores and pore volume
by the nitrogen adsorption method (DH method) are a value herein
measured by the method described in D. Dollion, G. R. Heal: J.
Appl. Chem., 14, 109 (1964).
[0101] The method for producing the catalyst having specific pore
distribution as described above is not particularly limited, but it
is usually important that the pore distribution (micropores and
mesopores in some cases) of the carrier is set to the pore
distribution described above. Specifically, as the method for
producing a carrier having micropores and mesopores, and a pore
volume of micropores of 0.3 cc/g carrier or more, the methods
described in publications such as JP 2010-208887 A (specification
of US 2011/318,254, the same applies hereafter) and WO 2009/75264 A
(specification of US 2011/058,308, the same applies hereafter) are
preferably used. Furthermore, as a method for producing a carrier
having micropores and mesopores, and having micropores with a mode
radius of pore distribution of 0.3 nm or more and less than 1 nm,
the methods described in publications such as JP 2010-208887 A and
WO 2009/75264 A are preferably used.
[0102] (Catalyst (b))
[0103] The catalyst (b) contains a catalyst carrier and a catalytic
metal supported on the catalyst carrier and satisfies the following
constitutions (b-1) to (b-3):
[0104] (b-1) the catalyst has pores with a radius of 1 nm or more
and less than 5 nm;
[0105] (b-2) a pore volume in the pores with a radius of 1 nm or
more and less than 5 nm is 0.8 cc/g carrier or more; and
[0106] (b-3) a specific surface area of the catalytic metal is 60
m.sup.2/g carrier or less.
[0107] According to the catalyst having the constitutions of the
(b-1) to (b-3) described above, filling of the pores of the
catalyst with water is suppressed, and then pores contributing to
transport of a reaction gas is sufficiently secured. As a result, a
catalyst excellent in gas transportability can be provided. In
detail, the volume of mesopores effective for gas transport is
sufficiently secured, and further, the specific surface area of the
catalytic metal is reduced, and thus the amount of the water
maintained in the mesopores in which the catalytic metal is
supported can be sufficiently reduced. Therefore, filling of the
inside of the mesopores with water is suppressed, thus gas such as
oxygen can be more efficiently transported to the catalytic metal
in the mesopores. In other words, the gas transport resistance in
the catalyst layer can be further reduced. As a result, the
catalytic reaction is promoted, and the catalyst (b) of this
embodiment can exhibit higher catalytic activity. Therefore, a
membrane electrode assembly and a fuel cell having a catalyst layer
using the catalyst (b) of this embodiment are excellent in power
generation performance.
[0108] FIG. 3 is a schematic explanatory cross-sectional view
illustrating the shape and structure of the catalysts (b) according
to an embodiment of the present invention. As illustrated in FIG.
3, the catalyst 20' of the present invention consists of a
catalytic metal 22' and a catalyst carrier 23'. The catalyst 20'
has pores 24' with a radius of 1 nm or more and less than 5 nm
(mesopores). The catalytic metal 22' is mainly supported inside the
mesopores 24'. Also, it is enough that at least a part of the
catalytic metal 22' is supported inside the mesopores 24', and a
part may be supported on the surface of the catalyst carrier 23'.
However, it is preferable that substantially all the catalytic
metal 22' is supported inside the mesopores 24', from the viewpoint
of preventing the contact between the electrolyte (electrolyte
polymer, ionomer) and the catalytic metal in the catalyst layer.
When the catalytic metal contacts the electrolyte, the area ratio
activity of the surface of the catalytic metal is reduced. On the
other hand, according to the above constitution, it is possible to
make the electrolyte not to enter the mesopores 24' of the catalyst
carrier 23', and thus the catalytic metal 22' and the electrolyte
can be physically separated. Moreover, three-phase interfaces can
be formed with water, and consequently the catalytic activity is
improved. The phrase "substantially all the catalytic metal" is not
particularly limited so long as it is the amount that can
sufficiently improve the catalytic activity. The "substantially all
the catalytic metal" is present in an amount of preferably 50% by
weight or more (upper limit: 100% by weight) and more preferably
80% by weight or more (upper limit: 100% by weight), in the whole
catalytic metal.
[0109] The pore volume of pores with a radius of 1 nm or more and
less than 5 nm (mesopores) in the catalyst (b) is 0.8 cc/g carrier
or more. The pore volume of mesopores is preferably 0.8 to 3 cc/g
carrier, and particularly preferably 0.8 to 2 cc/g carrier. In a
case where the pore volume is within the range described above,
pores contributing to transport of a reaction gas is much secured,
thus transport resistance of the reaction gas can be reduced.
Therefore, the reaction gas can be rapidly transported to the
surface of the catalytic metal stored in the mesopores, thus the
catalytic metal is effectively utilized. Furthermore, in a case
where the volume of mesopores is within the range described above,
the catalytic metal can be stored (supported) in the mesopores, and
the electrolyte and the catalytic metal in the catalyst layer can
be physically separated (contact between the electrolyte and the
catalytic metal can be more effectively suppressed and prevented).
As described above, in the embodiment in which the contact between
the catalytic metal in the mesopores and the electrolyte is
suppressed, the activity of the catalyst can be more effectively
utilized, as compared with the case where the amount of the
catalytic metal supported on the surface of the carrier is
high.
[0110] In addition, in the catalyst (b), the catalytic metal
(catalyst component) has a specific surface area of 60 m.sup.2/g
carrier or less. The catalytic metal has a specific surface area of
preferably 5 to 60 m.sup.2/g carrier, more preferably 5 to 30
m.sup.2/g carrier, and particularly preferably 10 to 25 m.sup.2/g
carrier. The surface of the catalytic metal is hydrophilic, and
water generated by catalytic reaction is likely to adsorb, thus
water is likely to be maintained in the mesopores in which the
catalytic metal is stored. When water is maintained in the
mesopores, gas transport path becomes narrow, and the diffusion
rate of the reaction gas in water is low, thus gas transportability
is reduced. On the other hand, when the specific surface area of
the catalytic metal is set relatively small as the above range, the
amount of water adsorbed to the surface of the catalytic metal can
be reduced. As a result, water is hard to be maintained in the
mesopores, and the water content in the catalyst and also in the
catalytic layer can be reduced. Therefore, transport resistance of
the reaction gas can be reduced, and the catalytic metal is
effectively utilized. The "specific surface area of the catalytic
metal" in the present invention can be measured by the method
described in, for example, Journal of Electroanalytical Chemistry
693 (2013) 34 to 41, or the like. The "specific surface area of the
catalytic metal" herein adopts the value measured by the following
method.
[0111] (Method for Measuring Specific Surface Area of Catalytic
Metal)
[0112] With regard to the cathode catalyst layer, electrochemical
effective surface area (ECA) is measured by cyclic voltammetry.
Hydrogen gas humidified so as to be saturated at a measurement
temperature is flowed into the opposed anode, and this anode is
used as a reference electrode and a counter electrode. Nitrogen gas
similarly humidified is flowed into the cathode, and valves of
entrance and exit of the cathode are closed immediately before
starting measurement, and nitrogen gas is sealed. Measurement is
performed in this state, in the following conditions, using an
electrochemical measuring system (manufactured by HOKUTO DENKO
CORP., model: HZ-5000).
[0113] [Formula 3]
Electrolyte solution: 1M sulfuric acid (manufactured by Wako Pure
Chemical Industries Ltd., for measurement of harmful metal)
Scanning rate: 50 mV/s Number of cycles: 3 cycles Lower limit
voltage value: 0.02 V Upper limit voltage value: 0.9 V
[0114] The method for producing the catalyst having specific pore
volume as described above is not particularly limited, but it is
usually important that the mesopore volume of the carrier is set to
the pore distribution described above. Specifically, as the method
for producing a carrier having mesopores, and a mesopore volume of
0.8 cc/g carrier or more, the methods described in publications
such as JP 2010-208887 A (specification of US 2011/318,254, the
same applies hereafter) and WO 2009/075264 A (specification of US
2011/058,308 A, the same applies hereafter) are preferably
used.
[0115] It is preferable that, in the catalysts (a) and (c), at
least apart of the catalytic metal is supported inside the
mesopores, and in the catalyst (b), at least a part of the
catalytic metal is supported inside the mesopores. Here, the size
of the catalytic metal supported in the mesopores when the
catalytic metal is supported in the mesopores is preferably larger
than the size of the mesopores (Embodiment (i)). According to the
constitution, the distance between the catalytic metal and the
inner wall of the pore of the carrier is reduced, and the space in
which water can be present is reduced, namely, the amount of water
adsorbed to the surface of the catalytic metal is reduced. Also,
water is subjected to interaction of the inner wall of the pore,
and thus a reaction of forming a metal oxide becomes slow, and a
metal oxide is hard to be formed. As a result, deactivation of the
surface of the catalytic metal can be further suppressed.
Therefore, the catalyst of this Embodiment (i) can exhibit higher
catalytic activity, namely, the catalytic reaction can be further
promoted.
[0116] In Embodiment (i), the mode radius (modal radius) of pore
distribution of mesopores (of the catalyst after supporting the
catalytic metal) is preferably 1 nm or more and 5 nm or less, more
preferably 1 nm or more and 4 nm or less, further preferably 1 nm
or more and 3 nm or less, and particularly preferably 1 nm or more
and 2 nm or less. With the mode radius of pore distribution as
described above, the sufficient amount of the catalytic metal can
be stored (supported) in the mesopores, and the electrolyte and the
catalytic metal in the catalyst layer can be physically separated
(contact between the catalytic metal and the electrolyte can be
more effectively suppressed and prevented). Therefore, the activity
of the catalytic metal can be more effectively utilized.
Furthermore, due to the presence of pores with large volume
(mesopores), the activity and effect of the present invention can
be more significantly exhibited so that the catalyst reaction can
be more effectively promoted.
[0117] In Embodiment (i), the average particle size of the
catalytic metal (catalytic metal particles) (of the catalyst after
supporting the catalytic metal) is preferably 2 nm or more and 7 nm
or less, and more preferably 3 nm or more and 5 nm or less. When
the average particle size of the catalytic metal is twice or more
of the mode radius of pore distribution as described above (when
the mode radius is half or less of the average particle size of the
catalytic metal), the distance between the catalytic metal and the
inner wall of the pore of the carrier is reduced, and the space in
which water can be present is reduced, namely, the amount of water
adsorbed to the surface of the catalytic metal is reduced. Also,
water is subjected to interaction of the inner wall, and thus a
reaction of forming a metal oxide becomes slow, and a metal oxide
is hard to be formed. As a result, deactivation of the surface of
the catalytic metal can be suppressed, and high catalytic activity
can be exhibited. Namely, the catalytic reaction can be promoted.
Also, the catalytic metal is relatively firmly supported in the
pores (mesopores), and the contact with the electrolyte in the
catalyst layer is more effectively suppressed and prevented.
Moreover, elution due to potential change is prevented, and
temporal performance deterioration can be also suppressed.
Therefore, catalytic activity can be further improved, namely, the
catalytic reaction can be more efficiently promoted.
[0118] (Catalyst (d))
[0119] The catalyst (d) contains a catalyst carrier and a catalytic
metal supported on the catalyst carrier and satisfies the following
constitutions (d-1) to (d-4):
[0120] (d-1) the catalyst has pores with a radius of 1 nm or more
having a mode radius of pore distribution of 1 nm or more and less
than 5 nm;
[0121] (d-2) the catalytic metal is supported inside the pores with
a radius of 1 nm or more;
[0122] (d-3) the mode radius is half or less of the average
particle size of the catalytic metal; and
[0123] (d-4) a pore volume in the pores with a radius of 1 nm or
more and less than 5 nm is 0.4 cc/g carrier or more. Meanwhile, as
described herein, "half of the average particle size (1/2 times of
the average particle size)" is also referred to as "average
particle radius."
[0124] According to the catalyst having the constitutions of the
(d-1) to (d-4) described above, by taking a constitution that the
catalytic metal is supported inside the pores (mesopores) in which
the electrolyte cannot enter, the catalytic metal inside the pores
forms three-phase interfaces with water, and the catalyst can be
effectively utilized. As a result, the activity of the catalyst can
be improved. In detail, particularly, the (d-3) the mode radius of
the pores is set to half or less of the average particle size of
the catalytic metal, and thus the distance between the catalytic
metal and the inner wall of the pore of the carrier is reduced, and
the space in which water can be present is reduced, namely, the
amount of water adsorbed to the surface of the catalytic metal is
reduced. Also, water is subjected to interaction of the inner wall
of the pore, and thus a reaction of forming a metal oxide becomes
slow, and a metal oxide is hard to be formed. As a result,
deactivation of the surface of the catalytic metal can be further
suppressed. Thus, the catalyst (d) of this embodiment can exhibit
high catalytic activity, namely, the catalytic action can be
promoted. Therefore, a membrane electrode assembly and a fuel cell
having a catalyst layer using the catalyst (d) of this embodiment
are excellent in power generation performance.
[0125] The catalyst (d) according to an embodiment of the present
invention contains a catalytic metal and a carrier. The catalyst
also has pores (mesopores). Herein, the catalytic metal is
supported inside the mesopores. Also, it is sufficient that at
least a part of the catalytic metal is supported inside the
mesopores, and a part may be supported in the surface of the
carrier. However, it is preferable that substantially all the
catalytic metal is supported inside the mesopores, from the
viewpoint of preventing the contact between the electrolyte and the
catalytic metal in the catalyst layer. The "substantially all the
catalytic metal" is not particularly limited so long as it is the
amount that can sufficiently improve the catalytic activity. The
"substantially all the catalytic metal" is present in an amount of
preferably 50% by weight or more (upper limit: 100% by weight) and
more preferably 80% by weight or more (upper limit: 100% by
weight), in the whole catalytic metal.
[0126] The pore volume of the mesopores of the catalyst (d) is 0.4
cc/g carrier or more, preferably 0.45 to 3 cc/g carrier, and more
preferably 0.5 to 1.5 cc/g carrier. When the pore volume is in the
above range, more catalytic metal can be stored (supported) in the
mesopores, and the electrolyte and the catalytic metal in the
catalyst layer can be physically separated (contact between the
catalytic metal and the electrolyte can be more effectively
suppressed and prevented). Therefore, the activity of the catalytic
metal can be more effectively utilized. In addition, by the
presence of many mesopores, the catalytic reaction can be more
effectively promoted.
[0127] The mode radius (modal radius) of pore distribution of the
pores of the catalyst (d) is 1 nm or more and less than 5 nm,
preferably 1 nm or more and 4 nm or less, more preferably 1 nm or
more and 3 nm or less, and further preferably 1 nm or more and 2 nm
or less. In the case of the mode radius of pore distribution as
described above, a sufficient amount of the catalytic metal can be
stored (supported) in the mesopores, and the electrolyte and the
catalytic metal in the catalyst layer can be physically separated
(contact between the catalytic metal and the electrolyte can be
more effectively suppressed and prevented). Therefore, the activity
of the catalytic metal can be more effectively utilized. In
addition, by the presence of pores with large volume (mesopores),
the action and effect according to the present invention are more
remarkably exhibited, and the catalytic reaction can be more
effectively promoted.
[0128] The method for producing the catalyst having specific pore
distribution as described above is not particularly limited, but it
is usually important that the mesopore volume of the carrier and so
on is set to the pore distribution described above. As the method
for producing those carriers, the methods described in publications
such as JP 2010-208887 A and WO 2009/075264 A are preferably
used.
[0129] (Catalyst Carrier)
[0130] The catalyst carrier contains carbon as a main component
(hereinbelow, also simply referred to as a "carrier"). The phrase
"contain(s) carbon as a main component" herein is a concept
containing both "consist(s) only of carbon" and "consist(s)
substantially of carbon", and an element other than carbon may be
contained. The phrase "consist(s) substantially of carbon" refers
to that 80% by weight or more of a whole, and preferably 95% by
weight or more of a whole (upper limit: less than 100% by weight)
consists of carbon.
[0131] The catalyst carrier is, although not particularly limited,
preferably carbon powder. Specifically, examples include carbon
powder made of carbon black (such as ketjen black, oil furnace
black, channel black, lamp black, thermal black and acetylene
black), and activated carbon.
[0132] The BET specific surface area of the catalyst carrier is
preferably 900 m.sup.2/g catalyst carrier or more, more preferably
1000 m.sup.2/g catalyst carrier or more, further preferably 1000 to
3000 m.sup.2/g catalyst carrier, particularly preferably 1100 to
1800 m.sup.2/g catalyst carrier. Since the specific surface area of
the catalyst carrier is substantially the same even when the
oxidative treatment and the catalyst metal supporting treatment are
performed as described later, the specific surface area between the
catalyst carrier precursor and the catalyst carrier is
substantially the same.
[0133] In the case of the specific surface area as described above,
sufficient mesopores and micropores that can be secured, thus while
securing micropores (lower gas transport resistance) sufficient for
gas transport, more catalytic metal can be stored (carried) in the
mesopores. Also, the electrolyte and the catalytic metal in the
catalyst layer can be physically separated (contact between the
electrolyte and the catalytic metal can be more effectively
suppressed and prevented). Therefore, the activity of the catalytic
metal can be more effectively utilized. In addition, as the
micropores function as a transport path of gas, a three-phase
interface with water is more significantly formed so that and the
catalytic reaction can be more effectively promoted.
[0134] According to this embodiment, part of the catalyst is coated
with an electrolyte so that clogging by the electrolyte of an
entrance of a mesopore in which a catalytic metal is supported can
be suppressed, and thus efficient transport of gas to the catalytic
metal can be achieved.
[0135] Furthermore, size of the catalyst carrier is not
particularly limited. From the viewpoint of easy supporting,
catalyst use rate, and controlling the thickness of an electrode
catalyst layer within a suitable range, the average particle size
(diameter) of the catalyst carrier is preferably 5 to 2000 nm, more
preferably 10 to 200 nm, and particularly preferably 20 to 100 nm.
As for the value of the "average particle size of a catalyst
carrier", unless specifically described otherwise, a value which is
measured by use of an observational means such as a scanning
electron microscope (SEM) and a transmission electron microscope
(TEM), and is calculated as an average value of particle size of
the particles observed in several to several tens of visual fields
is used. Similarly, the "particle size (diameter)" means, among the
lengths of a line going through a center of a particle connecting
any two points on a particle contour, the longest length.
[0136] When the catalyst satisfies the requirement of any of the
above constitutions (a) to (d), it is preferable that the catalyst
carrier also satisfies the same requirement of the constitutions
(a) to (d).
[0137] It is preferable that the catalyst carrier satisfies at
least one of the following constitutions (1) to (3). (1) (a-1) it
has pores with a radius of less than 1 nm (primary pore) and pores
with a radius of 1 nm or more (primary pore); and (a-2) a pore
volume in the pores with a radius of less than 1 nm is 0.3 cc/g
carrier or more. (2) (a-1) it has pores with a radius of less than
1 nm and pores with a radius of 1 nm or more; and (c-1) a mode
radius of pore distribution in the pores with a radius of less than
1 nm is 0.3 nm or more and less than 1 nm. (3) (d-1) the mode
radius of pore distribution in the pores with a radius of 1 nm or
more is 1 nm or more and less than 5 nm; and (d-4) a pore volume in
the pores with a radius of 1 nm or more and less than 5 nm is 0.4
cc/g carrier or more. Furthermore, in (3), it is preferable that
(b-2) a pore volume in the pores with a radius of 1 nm or more and
less than 5 nm is 0.8 cc/g carrier or more. More preferable range
of the pore volume of micropores in (a-2), mode radius of pore
distribution of micropores in (c-1), mode radius of pore
distribution of pores with a radius of 1 nm or more in (d-1), pore
volume of the pores with a radius of 1 nm or more and less than 5
nm in (d-4) and the like are the same as those described in the
sections of the catalysts (a) to (d).
[0138] (Catalytic Metal)
[0139] The catalytic metal constituting the catalyst has a function
of a catalytic action of an electrochemical reaction. The catalytic
metal used in the anode catalyst layer is not particularly limited
so long as it provides a catalytic action for the oxidation
reaction of hydrogen, and a known catalyst can be similarly used.
In addition, the catalytic metal used in the cathode catalyst layer
is not also particularly limited so long as it provides a catalytic
action for the reduction reaction of oxygen, and a known catalyst
can be similarly used. Specifically, the catalytic metal can be
selected from metals such as platinum, ruthenium, iridium, rhodium,
palladium, osmium, tungsten, lead, iron, copper, silver, chromium,
cobalt, nickel, manganese, vanadium, molybdenum, gallium, and
aluminum, as well as their alloys.
[0140] Of these, those that contain at least platinum are
preferably used, in order to improve catalytic activity,
anti-toxicity against carbon monoxide and the like, heat
resistance, and the like. Namely, the catalytic metal is preferably
platinum or contains platinum and a metal component other than
platinum, and is more preferably platinum or a platinum-containing
alloy. Such catalytic metal can exhibit high activity. When the
catalytic metal is platinum, in particular, platinum with small
particle size can be dispersed on a surface of carbon powder
(carrier), and thus the platinum surface are per weight can be
maintained even when the use amount of platinum is lowered.
Furthermore, when the catalytic metal contains platinum and a metal
component other than platinum, use amount of expensive platinum can
be lowered, and thus it is preferable from the economical point of
view. The alloy compositions should preferably contain 30 to 90
atom % of platinum, although it depends to the type of metal to be
alloyed, and the content of the metal to be alloyed with platinum
should be 10 to 70 atom %. Alloy is a collective name of a
combination of a metal element combined with one or more kinds of
metal elements or non-metallic elements, such combination having
metallic characteristics. The structure of an alloy can be an
eutectic alloy which is a mixture of crystals of different
component elements, a solid solution which is formed by completely
molten component elements, a compound where the component elements
are an intermetallic compound or a compound forming a compound of a
metal with a non-metal, or the like, and may be any of them in the
present application. In this case, the catalytic metal used in the
anode catalyst layer and the catalytic metal used in the cathode
catalyst layer may be appropriately selected from the above. Unless
otherwise noted herein, the descriptions for catalytic metals for
the anode catalyst layer and for the cathode catalyst layer have
the same definitions for both. However, the catalytic metals for
the anode catalyst layer and for the cathode catalyst layer need
not be the same, and may be appropriately selected so as to provide
the desired action described above.
[0141] The shape and size of the catalytic metal (catalyst
component) are not particularly limited, and any shape and size
similar to those of a known catalyst components can be adopted. For
example, those having granular, scaly, or layered shape can be
used, and granular shape is preferred.
[0142] The average particle size (diameter) of the catalytic metal
(catalytic metal particles) is not particularly limited. However,
it is preferably 3 nm or more, more preferably more than 3 nm and
30 nm or less, and particularly preferably more than 3 nm and 10 nm
or less. If an average particle size of the catalytic metal is 3 nm
or more, the catalytic metal is relatively firmly supported in the
carbon powder (for example, inside the mesopores of carbon powder),
and the contact with the electrolyte in the catalyst layer is more
effectively suppressed and prevented. In addition, when the
catalyst carrier has the micropores, the micropores are remained
without being blocked by the catalytic metal, and transport path of
gas is more favorably secured, and gas transport resistance can be
further reduced. Moreover, elution due to potential change is
prevented, and temporal performance deterioration can be also
suppressed. Therefore, catalytic activity can be further improved,
namely, the catalytic reaction can be more efficiently promoted. On
the other hand, if an average particle size of the catalytic metal
particles is 30 nm or less, the catalytic metal can be supported on
the catalyst carrier (for example, inside the mesopores of carbon
powder) by a simple method, and the electrolyte coating of the
catalytic metal can be reduced. In the case of using the catalyst
(a) and/or (c) as a catalyst, the average particle size of the
catalytic metal (catalytic metal particles) is preferably 3 nm or
more, more preferably more than 3 nm and 30 nm or less, and
particularly preferably more than 3 nm and 10 nm or less. In
addition, in the case of using the catalyst (b) as a catalyst, the
average particle size of the catalytic metal (catalytic metal
particles) is preferably more than 3 nm, more preferably more than
3 nm to 30 nm, and particularly preferably more than 3 nm to 10 nm.
If an average particle size of the catalytic metal is more than 3
nm, the specific surface area of the catalytic metal can be made
small. As a result, as described above, the amount of water
adsorbed to the surface of the catalytic metal can be reduced, and
mesopores contributing to transport of a reaction gas can be
secured in a large amount. Therefore, transport resistance of the
reaction gas can be reduced. Moreover, elution due to potential
change is prevented, and temporal performance deterioration can be
also suppressed. Therefore, catalytic activity can be further
improved, namely, the catalytic reaction can be more efficiently
promoted. On the other hand, if an average particle size of the
catalytic metal particles is 30 nm or less, the catalytic metal can
be supported inside the mesopores of the carrier by a simple
method, and the electrolyte coating of the catalytic metal can be
reduced. Furthermore, in the case of using the catalyst (d) as a
catalyst, the average particle size of the catalytic metal is twice
or more of the mode radius of pore distribution of mesopores (the
mode radius is half or less of the average particle size of the
catalytic metal). Here, the average particle size of the catalytic
metal (catalytic metal particles) is preferably 2 nm or more and 7
nm or less, and more preferably 3 nm or more and 5 nm or less. When
the average particle size of the catalytic metal is twice or more
of the mode radius of pore distribution as described above, the
distance between the catalytic metal and the inner wall of the pore
of the carrier is reduced, and the space in which water can be
present is reduced, namely, the amount of water adsorbed to the
surface of the catalytic metal is reduced. Also, water is subjected
to interaction of the inner wall, and thus a reaction of forming a
metal oxide becomes slow, and a metal oxide is hard to be formed.
As a result, deactivation of the surface of the catalytic metal can
be suppressed, and high catalytic activity can be exhibited.
Namely, the catalytic reaction can be promoted. Also, the catalytic
metal is relatively firmly supported in the pores (mesopores), and
the contact with the electrolyte in the catalyst layer is more
effectively suppressed and prevented. Moreover, elution due to
potential change is prevented, and temporal performance
deterioration can be also suppressed. Therefore, catalytic activity
can be further improved, namely, the catalytic reaction can be more
efficiently promoted.
[0143] Meanwhile, the "average particle size of the catalytic metal
particles" or the "average particle radius of the catalytic metal
particles" in the present invention can be determined as the
crystallite radius obtained from the half-band width of the
diffraction peak of the catalytic metal component in the X-ray
diffraction, or an average value of the particle diameter of the
catalytic metal particles examined by using a transmission-type
electron microscope (TEM). The "average particle size of the
catalytic metal particles" or the "average particle radius of the
catalytic metal" herein is a crystallite radius obtained from the
half-band width of the diffraction peak of the catalytic metal
component in the X-ray diffraction.
[0144] The content of the catalytic metal per unit catalyst coated
area (mg/cm.sup.2) is not particularly limited so long as
sufficient dispersion degree of the catalyst on the carrier and
power generation performance are obtained, and it is, for example,
1 mg/cm.sup.2 or less. However, in a case where the catalyst
contains platinum or a platinum-containing alloy, the platinum
content per unit catalyst coated area is preferably 0.5 mg/cm.sup.2
or less. Use of an expensive noble metal catalyst represented by
platinum (Pt) or platinum alloy is a reason for yielding a fuel
cell with high price. As such, it is preferable to cut the cost by
lowering the use amount of expensive platinum (platinum content) to
the aforementioned range. The lower limit value is not particularly
limited so long as power generation performance is obtained, and it
is 0.01 mg/cm.sup.2 or more, for example. More particularly, the
platinum content is 0.02 to 0.4 mg/cm.sup.2. In the catalyst layer
of this embodiment, electrolyte coating by a catalytic metal is
suppressed so that the activity per catalyst weight can be
improved. Accordingly, it is possible to reduce the use amount of a
highly expensive catalyst.
[0145] In the present specification, the induction coupled plasma
emission spectrometry (ICP) is used for measuring (confirming) the
"catalytic metal (platinum) content per unit catalyst coated area
(mg/cm.sup.2)". The method for obtaining desired "catalytic metal
(platinum) content per unit catalyst coated area (mg/cm.sup.2)" can
be also easily performed by a person skilled in the art, and the
adjustment of the composition (catalyst concentration) and coating
amount of slurry allows the control of the amount.
[0146] In addition, the supported amount of a catalytic metal in
the carrier (also referred to as "supporting rate") is preferably
10 to 80% by weight, and more preferably 20 to 70% by weight
relative to the whole amount of the catalyst (carrier and catalyst
metal). The supported amount in the above-mentioned range is
preferable by reason of allowing sufficient dispersion degree of
the catalyst components on the carrier, the improvement in power
generation performance, the economic advantages, and the catalytic
activity per unit weight. Here, the "catalyst supporting rate" in
the present invention is a value obtained by measuring the weights
of the carrier before supporting the catalytic metal and the
catalyst after supporting the catalytic metal.
[0147] (Polymer Electrolyte)
[0148] The polymer electrolyte is not particularly limited, but it
is preferably a polymer electrolyte with ion conductivity. From the
viewpoint of transferring protons that are generated near a
catalyst active material on fuel electrode side, the polymer
electrolyte is also referred to as a proton conductive polymer.
[0149] The polymer electrolyte is not particularly limited, and the
conventionally known knowledge can be properly referred to. The
polymer electrolyte is roughly divided into a fluorine-based
polymer electrolyte and a hydrocarbon-based polymer electrolyte,
depending on the kind of ion exchange resin that is a constituent
material. Among them, a fluorine-based polymer electrolyte is
preferred as a polymer electrolyte. By having the constitution of
(I) above, the catalyst of this embodiment exhibits a more
hydrophilic-like property even under conditions in which R' value
is 0.6 or less. As such, it becomes difficult for the electrolyte
to adsorb onto a catalyst even when the fluorine-based polymer
electrolyte with high hydrophobicity is used, and thus it is more
likely that the effect of the present invention is obtained at high
level. Furthermore, from the viewpoint of having excellent heat
resistance, chemical stability, durability, and mechanical
strength, the fluorine-based polymer electrolyte is preferable.
[0150] Examples of the ion exchange resin that constitutes a
fluorine-based polymer electrolyte include perfluorocarbon sulfonic
acid based polymers such as Nafion (registered trademark,
manufactured by Du Pont), Aciplex (registered trademark,
manufactured by Asahi Kasei Corporation Ltd.), and Flemion
(registered trademark, manufactured by Asahi Glass Co., LTD.),
trifluorostyrene sulfonic acid based polymers, ethylene
tetrafluoroethylene-g-styrene sulfonic acid based polymers,
polyvinylidene fluoride-perfluorocarbon sulfonic acid based
polymers, and the like. Among them, a fluorine-based polymer
electrolyte consisting of a perfluorocarbon sulfonic acid based
polymer is used.
[0151] The hydrocarbon-based electrolyte specifically includes
sulfonated polyether sulfon (S-PES), sulfonated polyaryl ether
ketone, sulfonated polybenzimidazole alkyl, phosphonated
polybenzimidazole alkyl, sulfonated polystyrene, sulfonated
polyether ether ketone (SPEEK), sulfonated polyphenylene (S-PPP),
and the like.
[0152] The above-mentioned ion exchange resins may be used singly
in only one kind or in combinations of two or more kinds. Also, the
above-mentioned materials are not exclusive, and other materials
can be used as well.
[0153] The conductivity of protons is important in the polymer
electrolyte which is responsible for proton transfer. Here, in a
case where EW of the polymer electrolyte is too large, ion
conductivity of the whole catalyst layer deteriorates. Accordingly,
the catalyst layer of this embodiment preferably contains the
polymer electrolyte with small EW. Specifically, the catalyst layer
of this embodiment contains preferably a polymer electrolyte with
EW of 1500 g/eq. or less, more preferably a polymer electrolyte
with EW of 1200 g/eq. or less, and particularly preferably a
polymer electrolyte with EW of 1000 g/eq. or less.
[0154] Meanwhile, in a case where EW is too small, the
hydrophillicity is so high that smooth movement of water becomes
difficult. From this point of view, EW of a polymer electrolyte is
preferably 600 g/eq or more. Meanwhile, EW (Equivalent Weight)
represents the equivalent weight of an exchange group with proton
conductivity. The equivalent weight is dry weight of an ion
exchange membrane per equivalent of the ion exchange group, and
represented by a unit of "g/eq".
[0155] In addition, the catalyst layer contains two or more kinds
of polymer electrolytes with different EW in the power generation
surface, and it is preferable to use a polymer electrolyte with a
lowest EW among polymer electrolytes in a region in which a
relative humidity of gas in a passage is 90% or less. By adopting
such material arrangement, the resistance value becomes small,
irrespective of the current density region, and cell performance
can be improved. EW of the polymer electrolyte used in a region in
which a relative humidity of gas in a passage is 90% or less, that
is, the polymer electrolyte with a lowest EW is preferably 900
g/eq. or less. Accordingly, the above-mentioned effects are more
secured and remarkable.
[0156] Furthermore, it is desirable to use the polymer electrolyte
with a lowest EW in a region with a temperature higher than the
average temperature of the inlet and outlet of cooling water.
Accordingly, the resistance value becomes small, irrespective of
the current density region, and cell performance can be further
improved.
[0157] Furthermore, it is desirable to use the polymer electrolyte
with a lowest EW in a region within the range of 3/5 from at least
one of gas supply ports of fuel gas and oxidant gas, with respect
to the passage length, from the viewpoint of reducing the
resistance value of fuel cell system.
[0158] The catalyst layer may contain an additive such as a
water-repellent agent such as polytetrafluoroethylene,
polyhexafluoropropylene or tetrafluoroethylene-hexafluoropropylene
copolymer, a dispersing agent such as a surfactant, a thickener
such as glycerin, ethylene glycol (EG), polyvinyl alcohol (PVA) or
propylene glycol (PG), and a pore-forming material, as
necessary.
[0159] The thickness of the catalyst layer (dry film thickness) is
preferably 0.05 to 30 .mu.m, more preferably 1 to 20 .mu.m, and
further preferably 2 to 15 .mu.m. Meanwhile, the above thickness is
applied to both the cathode catalyst layer and the anode catalyst
layer. However, the thicknesses of the cathode catalyst layer and
the anode catalyst layer may be the same or different from each
other.
[0160] (Method for Producing Catalyst)
[0161] Preferable method for producing catalyst of this embodiments
will be described below.
[0162] The method for producing the catalyst is not particularly
limited, but it is preferable that a catalytic metal is supported
on a catalyst carrier and then subjected to a treatment with an
oxidative treatment solution. Namely, the method for producing the
fuel cell electrode catalyst of this embodiment preferably has
supporting a catalytic metal containing platinum on a catalyst
carrier precursor to obtain a catalyst powder and treating the
catalyst powder with an oxidative treatment solution to obtain the
catalyst.
1. Step of Supporting a Catalytic Metal Containing Platinum on a
Catalyst Carrier Precursor to Obtain a Catalyst Powder
[0163] The catalyst carrier precursor is preferably obtained by a
heat treatment of a carbon material. According to a heat treatment,
a catalyst carrier precursor having R' value (D'/G intensity ratio)
of 0.6 or less can be obtained.
[0164] The BET specific surface area of a carbon material is not
particularly limited, but is preferably 900 m.sup.2/g or more, more
preferably 1000 to 3000 m.sup.2/g, even more preferably 1100 to
1800 m.sup.2/g, and particularly preferably 1200 to 1800 m.sup.2/g
in order for the BET specific surface area of the catalyst to
satisfy the above constitution (III). In the case of the specific
surface area as described above, a sufficient gas transportability
(lower gas transport resistance) and performance (supporting a
sufficient amount of the catalytic metal) can be achieved. In
addition, by using a carrier with large BET specific surface area
in particular, more efficient supporting (storing) of the catalytic
metal inside a carrier (in particular, mesopore) can be
achieved.
[0165] It is preferable that the carbon material satisfies at least
one of the following constitutions (1) to (3). (1) (a-1) it has
pores with a radius of less than 1 nm (primary pore) and pores with
a radius of 1 nm or more (primary pore); and (a-2) a pore volume of
the pores with a radius of less than 1 nm is 0.3 cc/g carrier or
more. (2) (a-1) it has pores with a radius of less than 1 nm and
pores with a radius of 1 nm or more; and (c-1) the mode radius of
pore distribution of the pores with a radius of less than 1 nm is
0.3 nm or more and less than 1 nm. (3) (d-1) the mode radius of
pore distribution of the pores with a radius of 1 nm or more is 1
nm or more and less than 5 nm; and (d-4) a pore volume of the pores
with a radius of 1 nm or more and less than 5 nm is 0.4 cc/g
carrier or more. Furthermore, in (3), it is preferable that (b-2) a
pore volume of the pores with a radius of 1 nm or more and less
than 5 nm is 0.8 cc/g carrier or more. More preferred range of the
pore volume of micropores in (a-2), mode radius of pore
distribution of micropores in (c-1), mode radius of pore
distribution of pores with a radius of 1 nm or more in (d-1), pore
volume of the pores with a radius of 1 nm or more and less than 5
nm in (d-4) and the like are the same as those described in the
sections of the catalysts (a) to (d).
[0166] The carbon material is produced by a method described in the
publications such as JP 2010-208887 A or WO 2009/75264 A. The
conditions of the heat treatment for obtaining a carbon material
having desired pores are different depending on the material, and
are properly determined so as to obtain a desired porous structure.
Generally, the high heating temperature brings a tendency for a
mode size of the pore distribution to shift toward the direction of
a large pore diameter. Therefore, such heat treatment conditions
may be determined in accordance with the material while confirming
the porous structure and it can be easily determined by a person
skilled in the art.
[0167] The material of the carbon material is not particularly
limited, as long as it contains carbon as a main component.
However, a material allowing easy formation of a catalyst carrier
satisfying the aforementioned R' value or the aforementioned BET
specific surface area is preferable. In addition, the material that
can form pores having pore volume or mode size (primary pores)
inside the carrier and has sufficient specific surface area and
sufficient electron conductivity for supporting the catalyst
component inside the mesopores in a dispersion state is preferable.
Specifically, examples include carbon powder made of carbon black
(such as ketjen black, oil furnace black, channel black, lamp
black, thermal black and acetylene black), and activated carbon.
The phrase "the main component is carbon" indicates that carbon
atoms are contained as the main component, and is a concept
including both "consisting only of carbon atoms" and "consisting
substantially of carbon atoms", and elements except carbon atoms
may be contained. The phrase "consisting substantially of carbon
atoms" indicates that the mixing of approximately 2 to 3% by weight
or less of impurities is allowable.
[0168] Furthermore, the average particle size (average secondary
particle size) of the carbon material is not particularly limited,
but it is preferably 20 to 100 nm. From the viewpoint of easy
supporting, catalyst use rate, or the like, the average particle
size (average primary particle size) of the carbon material is 1 to
10 nm, and preferably 2 to 5 nm. When it is within this range,
mechanical strength is maintained even when the aforementioned pore
structure is formed on the carrier, and the catalyst layer can be
controlled within a suitable range. As for the value of the
"average particle size of a carbon material", unless specifically
described otherwise, a value which is measured by use of an
observational means such as a scanning electron microscope (SEM)
and a transmission electron microscope (TEM), and is calculated as
an average value of particle size of the particles observed in
several to several tens of visual fields is used. Similarly, the
"particle size (diameter)" means, among the lengths of a line going
through a center of a particle connecting any two points on a
particle contour, the longest length.
[0169] The conditions for a heat treatment of a carbon material are
not particularly limited, but the treatment is performed so as to
obtain a catalyst carrier precursor satisfying the above
constitution (II) (R' value (D'/G intensity ratio) is 0.6 or less)
and the constitution (III) (BET specific surface area is at least
900 m.sup.2/g). Specifically, the heat treatment temperature is
preferably 1300.degree. C. or more and 1880.degree. C. or less,
more preferably 1380 to 1880.degree. C., and even more preferably
1400 to 1860.degree. C. For the heat treatment, the temperature
increase rate is preferably 100 to 1000.degree. C./hour and is
particularly preferably 300 to 800.degree. C./hour. The heat
treatment time (retention time at a predetermined heat treatment
temperature) is preferably 1 to 10 minutes, and particularly
preferably 2 to 8 minutes. The heat treatment can be performed in
an air atmosphere, or an inert atmosphere such as argon gas or a
nitrogen gas. In such conditions, carbon powder for satisfying the
above R' value as the constitution (II), or the R' value of the
constitution (II) and the specific surface area of the constitution
(III) is conveniently obtained. In addition, with the above
conditions, carbon powder satisfying the R value of the
constitution (II') is also conveniently obtained. Meanwhile, when
the heat treatment conditions are less than the above lower limit
(heat treatment conditions are too mild), there is a possibility
that the edge amount of carbon (graphene) is not sufficiently
lowered. On the other hands, when the heat treatment conditions are
more than the above upper limit (heat treatment conditions are too
severe), there is a possibility that graphitization proceeds too
much, and the BET specific surface area of carbon (graphene)
becomes too small.
[0170] The resultant obtained by a heat treatment of the carbon
material corresponds to a catalyst carrier precursor.
[0171] Even when the oxidation treatment and the treatment for
supporting a catalytic metal that are described below are
performed, the R' value of the catalyst is substantially the same
as the R' value of the catalyst carrier precursor. As such, in
order for the catalyst to satisfy the condition of the above (II)
(D'/G intensity ratio is 0.6 or less), it is preferable that the
catalyst carrier precursor also satisfies the above (II). Namely,
the catalyst carrier precursor which is used for obtaining the
catalyst used in the catalyst layer of this embodiment satisfies
the following: R' (D'/G intensity ratio), which is the ratio of D'
band peak intensity (D' intensity) measured in the vicinity of 1620
cm.sup.-1 relative to G band peak intensity (G intensity) measured
in the vicinity of 1580 cm.sup.-1 by Raman spectroscopy, is 0.6 or
less. The R' (D'/G intensity ratio) of the catalyst carrier
precursor is preferably 0 to 0.6 and more preferably 0 to 0.51.
[0172] In addition to above, even when the oxidation treatment and
the treatment for supporting a catalytic metal that are described
below are performed, the R value of the catalyst is substantially
the same as the R value of the catalyst carrier precursor. As such,
in order for the catalyst to satisfy the condition of the above
(II'), it is preferable that the catalyst carrier precursor also
satisfies that (II') R (D/G intensity ratio), which is the ratio of
D intensity relative to G intensity, is 1.7 or more. Furthermore,
the R (D/G intensity ratio) of the catalyst carrier precursor is
more preferably more than 1.75 and 2.5 or less, and even more
preferably 1.8 to 2.4.
[0173] Furthermore, when the catalyst satisfies the above condition
(III), it is preferable that (III) the BET specific surface area of
the catalyst carrier precursor is also 900 m.sup.2/g or more per
weight. That is because, the specific surface area of the catalyst
carrier remains the same even when the oxidation treatment and the
treatment for supporting a catalytic metal that are described below
are performed and most of the specific surface area of a catalyst
belongs to the catalyst carrier. Thus, the BET specific surface
area of the catalyst carrier precursor is more preferably 1000
m.sup.2/g or more, even more preferably 1000 to 3000 m.sup.2/g
carrier, and particularly preferably 1100 to 1800 m.sup.2/g
carrier. In the case of the specific surface area as described
above, sufficient mesopores and also, in some cases, sufficient
micropores can be secured, and thus more catalytic metal can be
stored (supported) in the mesopores with better dispersibility.
Also, mesopores and also micropores in some cases sufficient for
gas transport can be secured, thus gas transport resistance can be
further reduced. In addition, the electrolyte and the catalytic
metal in the catalyst layer can be physically separated (contact
between the electrolyte and the catalytic metal can be more
effectively suppressed and prevented). Therefore, the activity of
the catalytic metal can be more effectively utilized. Moreover,
local flux in the vicinity of the catalytic metal particles becomes
small, thus a reaction gas is rapidly transported, and the
catalytic metal is effectively utilized. Also, by the presence of
many pores (mesopores) and micropores in some cases, the catalytic
reaction can be more effectively promoted. Also, the balance
between dispersibility of the catalyst component on the catalyst
carrier and effective utilization rate of the catalyst component
can be properly controlled. In addition, the micropores act as a
transport path of gas, and three-phase interfaces are more
remarkably formed by water, thus catalytic activity can be further
improved.
[0174] Subsequently, a catalytic metal is supported on the catalyst
carrier precursor to obtain a catalyst powder.
[0175] The method for supporting the catalytic metal on the
catalyst carrier precursor is not particularly limited. Preferably,
the method includes (i) a step of precipitating a catalytic metal
on the surface of the catalyst carrier (precipitation step) and
(ii) a step of performing a heat treatment, after the precipitation
step, to increase the particle size of the catalytic metal (heat
treatment step). The above method increases the particle size of
the catalytic metal by performing a heat treatment after
precipitation. Therefore, a catalytic metal with a large particle
size can be supported inside the pores (especially mesopores) of
the catalyst carrier.
[0176] A preferred embodiment of the method for producing the
catalyst will be described below, but the present invention is not
limited to the following embodiment.
[0177] (i) Deposition Step
[0178] In this step, the catalyst metal is deposited on the surface
of the catalytic carrier precursor. This step is a known method,
and for example, a method of immersing a catalyst carrier precursor
in a precursor solution of the catalytic metal, followed by
reducing is preferably used.
[0179] The precursor of the catalytic metal is not particularly
limited, and properly selected depending on the kind of the
catalytic metal to be used. Specifically, chlorides, nitrates,
sulfates, chlorides, acetates and amine compounds of the catalytic
metal such as above-mentioned platinum and the like can be
exemplified. More specifically, chlorides such as platinum chloride
(hexachloroplatinate hexahydrate), palladium chloride, rhodium
chloride, ruthenium chloride and cobalt chloride, nitrates such as
palladium nitrate, rhodium nitrate and iridium nitrate, sulfates
such as palladium sulfate and rhodium sulfate, acetates such as
rhodium acetate, ammine compounds such as dinitrodiammine platinum
nitric acid and dinitrodiammine palladium and the like are
preferably exemplified. Also, the solvent used to prepare the
precursor solution of the catalytic metal is not particularly
limited so long as it can dissolve the precursor of the catalytic
metal, and it is properly selected depending on the kind of the
precursor of the catalytic metal to be used. Specific examples
include water, acids, alkalis, organic solvents and the like. The
concentration of the precursor of the catalytic metal in the
precursor solution of the catalytic metal is not particularly
limited, and is preferably 0.1 to 50% by weight and more preferably
0.5 to 20% by weight, when converted in terms of metal.
[0180] The reducing agent includes hydrogen, hydrazine, sodium
thiosulfate, citric acid, sodium citrate, L-ascorbic acid, sodium
borohydride, formaldehyde, methanol, ethanol, ethylene, carbon
monoxide, and the like. A gaseous substance at normal temperature
such as hydrogen can also be supplied by bubbling. The amount of
the reducing agent is not particularly limited so long as it is the
amount that can reduce the precursor of the catalytic metal to a
catalytic metal, and the known amount is similarly applicable.
[0181] The deposition conditions are not particularly limited so
long as the catalytic metal can be deposited on a catalyst carrier
precursor. For example, the deposition temperature is preferably a
temperature around the boiling point of the solvent, and more
preferably a room temperature to 100.degree. C. Also, the
deposition time is preferably 1 to 10 hours and more preferably 2
to 8 hours. The precipitation step may be performed while stirring
and mixing, as necessary.
[0182] Accordingly, the precursor of the catalytic metal is reduced
to a catalytic metal, and the catalytic metal is deposited
(supported) on the catalyst carrier precursor.
[0183] (ii) Heat Treatment Step
[0184] In this step, after the (i) deposition step, a heat
treatment is performed to increase the particle size of the
catalytic metal.
[0185] The heat treatment condition is not particularly limited so
long as it is the condition that can increase the particle size of
the catalytic metal. For example, the heat treatment temperature is
preferably 300 to 1200.degree. C., more preferably 500 to
1150.degree. C., and particularly preferably 700 to 1000.degree. C.
Also, the heat treatment time is preferably 0.02 to 3 hours, more
preferably 0.1 to 2 hours, and particularly preferably 0.2 to 1.5
hours. The heat treatment step may be performed in a hydrogen
atmosphere.
[0186] Accordingly, the particle size of the catalytic metal can be
increased in the catalyst carrier precursor (especially, in the
mesopores of the catalyst carrier precursor). Therefore, the
catalytic metal particles are hard to desorb (from the catalyst
carrier) to the outside of the system. Therefore, the catalyst can
be more effectively utilized.
2. Step of Treating a Catalyst Powder with Oxidative Treatment
Solution to Obtain a Catalyst
[0187] Subsequently, a catalyst powder is obtained by supporting a
catalytic metal containing platinum, and the catalyst powder is
preferably treated with an oxidative treatment solution.
[0188] According to a treatment with an oxidative solution, the
carrier can be provided with an acidic group so that the
hydrophillicity of a carrier can be improved. Accordingly, the
catalyst satisfying the above condition (I) in which the volume
ratio of a water vapor adsorption amount compared to a nitrogen
adsorption amount is 0.15 or more and 0.30 or less can be easily
obtained.
[0189] Preferred examples of the oxidative solution which is used
include an aqueous solution of sulfuric acid, nitric acid,
phosphite acid, potassium permanganate, hydrogen peroxide,
hydrochloric acid, chloric acid, hypochlorous acid, chromic acid,
or the like. Meanwhile, the treatment with an oxidative solution is
performed by contacting, one or more times, the catalyst with an
oxidative solution. When an acid treatment is performed several
times, the type of the solution can be varied for each treatment.
As for the condition for treatment with an oxidative solution, the
solution concentration is preferably 0.1 to 10.0 mol/L and the
catalyst is preferably immersed in the solution. The time for
immersion is preferably 0.5 to 3 hours. The treatment temperature
is preferably 50 to 90.degree. C. The volume ratio of a water vapor
adsorption amount compared to a nitrogen adsorption amount or the
amount of an acidic group in the carrier can be controlled by
adjusting the BET specific surface area of a catalyst, type of an
oxidative solution, treatment time, and treatment temperature.
[0190] (Method for Producing Catalyst Layer)
[0191] The method for producing the catalyst layer using the above
obtained catalyst is not particularly limited, and for example, the
known methods such as the method described in JP 2010-21060 A are
applied, or properly modified and applied.
[0192] Preferably, the method includes a step for producing a
catalyst layer of the following 3. using a catalyst obtained by the
above mentioned 1. and 2.
3. Step of Preparing the Catalyst Layer
[0193] Subsequently, a catalyst ink containing the catalyst
obtained above, a polymer electrolyte and a solvent is prepared.
The solvent is not particularly limited, and the normal solvent
used in forming a catalyst layer can be similarly used. Specific
examples include water, cyclohexanol, lower alcohols with a carbon
number of 1 to 4, propylene glycol, benzene, toluene, xylene and
the like. Other than these, acetic acid butyl alcohol, dimethyl
ether, ethylene glycol and the like may be used as a solvent. These
solvents may be used singly in one kind or in mixed liquid of two
or more kinds.
[0194] Among them, a water-alcohol mixed solvent with a high
content ratio of water is preferably used as the solvent. It is
preferable to use a mixed solvent with a high content ratio of
water as a dispersion medium, because it can prevent electrolyte
from coating the entrance of mesopores. Here, a mixed weight ratio
of water and alcohol (water/alcohol) is preferably 55/45 to 95/5,
and more preferably 60/40 or more and less than 91/9, and even more
preferably 65/35 to 90/10.
[0195] Water is not particularly limited, and tap water, pure
water, ion-exchange water, distilled water and the like can be
used. Also, alcohol is not particularly limited. Specific examples
include methanol, ethanol, 1-propanol, 2-propanol, 1-butanol,
2-methyl-1-propanol, 2-butanol, 2-methyl-2-propanol, cyclohexanol,
and the like. Among them, methanol, ethanol, 1-propanol,
2-propanol, 1-butanol, 2-methyl-1-propanol, 2-butanol and
2-methyl-2-propanol are preferable. By using such high affinity
lower alcohol, extremely uneven distribution of the electrolyte can
be prevented. Furthermore, among the above alcohols, alcohol with
boiling point of lower than 100.degree. C. is preferably used.
Examples of the alcohol with boiling point of lower than
100.degree. C. include alcohol selected from a group consisting of
methanol (boiling point: 65.degree. C.), ethanol (boiling point:
78.degree. C.), 1-propanol (boiling point: 97.degree. C.),
2-propanol (boiling point: 82.degree. C.), and 2-methyl-2-propanol
(boiling point: 83.degree. C.). The alcohol can be used singly in
only one kind or in a mixture of two or more kinds.
[0196] As described above, the polymer electrolyte is roughly
classified into a fluorine-based polymer electrolyte and a
hydrocarbon-based polymer electrolyte, depending on the kind of ion
exchange resin which is a constituent material. Among them, the
electrolyte is preferably a fluorine-based polymer electrolyte. By
using a hydrophobic fluorine-based polymer electrolyte as described
above, the electrolyte is further likely to agglomerate with
increasing water content in the solvent.
[0197] The amount of the solvent constituting the catalyst ink is
not particularly limited so long as it is an amount such as to
allow the electrolyte to be completely dissolved. Specifically, the
concentration of the solid matter containing the catalyst powder,
the polymer electrolyte and the like is preferably 1 to 50% by
weight and more preferably about 5 to 30% by weight in the
electrode catalyst ink.
[0198] Meanwhile, in the case of using additives such as
water-repellent agent, dispersing agent, thickener and pore-forming
material, these additives may be added to the catalyst ink. In this
case, the addition amount of the additives is not particularly
limited so long as it is an amount such as not to disturb the above
effect of the present invention. For example, the addition amount
of each of the additives is preferably 5 to 20% by weight, with
respect to the whole weight of the electrode catalyst ink.
[0199] Next, the catalyst ink is applied on the surface of a
substrate. An application method on the substrate is not
particularly limited and known methods can be used. Specifically,
the application can be performed using a known method such as spray
(spray coating) method, Gulliver printing method, die coater
method, screen printing method, and doctor blade method.
[0200] On this occasion, a solid polymer electrolyte membrane (an
electrolyte layer) or a gas diffusion substrate (a gas diffusion
layer) can be used as the substrate onto which the catalyst ink is
applied. In such a case, after forming the catalyst layer on the
surface of a solid polymer electrolyte membrane (an electrolyte
membrane) or a gas diffusion substrate (a gas diffusion layer), an
obtained laminated body may be directly used for producing a
membrane electrode assembly. Alternatively, the catalyst layer may
be obtained by forming the catalyst layer on the substrate which is
a peelable substrate such as polytetrafluoroethylene (PTFE) [Teflon
(registered trademark)] sheet, and then peeling the catalyst layer
portion off the substrate.
[0201] Lastly, a coated layer (membrane) of the catalyst ink is
dried under the room atmosphere or an inert gas atmosphere at room
temperature to 150.degree. C. for 1 to 60 minutes. Thus, the
catalyst layer is formed.
[0202] [Membrane Electrode Assembly]
[0203] According to further another embodiment of the present
invention, a membrane electrode assembly for fuel cell containing
the above electrode catalyst for fuel cell or the above electrode
catalyst layer for fuel cell is provided. Namely, a fuel cell
membrane electrode assembly having a solid polymer electrolyte
membrane 2, a cathode catalyst layer arranged on one side of the
electrolyte membrane, an anode catalyst layer arranged on the other
side of the electrolyte membrane, and a pair of gas diffusion
layers (4a and 4c) which sandwich the electrolyte membrane 2, the
anode catalyst layer 3a and the cathode catalyst layer 3c is
provided. Then, in this membrane electrode assembly, at least one
of the cathode catalyst layer and the anode catalyst layer is the
catalyst layer of the embodiment described above.
[0204] However, in consideration of the necessity for the
improvement in proton conductivity and the improvement in the
transport property (the gas diffusion property) of reactant gas
(especially O.sub.2), at least the cathode catalyst layer is
preferably the catalyst layer of the embodiment described above.
However, the catalyst layer according to the above-mentioned
embodiment is not particularly limited; for example, the catalyst
layer may be used as the anode catalyst layer, or as both the
cathode catalyst layer and the anode catalyst layer.
[0205] According to further another embodiment of the present
invention, a fuel cell having the membrane electrode assembly of
the above-mentioned embodiment is provided. Namely, an embodiment
of the present invention is a fuel cell having a pair of an anode
separator and a cathode separator which sandwich the membrane
electrode assembly of the above-mentioned embodiment.
[0206] The constituents of the PEFC 1 using the catalyst layer
according to the above-mentioned embodiment will be described below
with reference to FIG. 1. However, the characteristics of the
present invention lie in the catalyst layer. Therefore, the
specific constitutions of members except the catalyst layer
constituting the fuel cell may be properly modified with reference
to the conventionally known knowledge.
[0207] (Electrolyte Membrane)
[0208] The electrolyte membrane consists of, for example, a solid
polymer electrolyte membrane 2 such as can be seen in the
constitution illustrated in FIG. 1. This solid polymer electrolyte
membrane 2 has the function of allowing the protons generated in an
anode catalyst layer 3a to be selectively transmitted to a cathode
catalyst layer 3c along the membrane thickness direction during the
operation of a PEFC 1. Also, the solid polymer electrolyte membrane
2 serves as a partition wall to prevent the fuel gas supplied to
the anode side from mixing with the oxidant gas supplied to the
cathode side.
[0209] An electrolyte material composing the solid polymer
electrolyte membrane 2 is not particularly limited, and can be
properly referred to the conventionally known knowledge. For
example, the fluorine-based polymer electrolyte and the
hydrocarbon-based polymer electrolyte, which are described as the
polymer electrolyte in the above, may be used. On this occasion, it
is not necessary to use the same as the polymer electrolyte used
for the catalyst layer.
[0210] The thickness of the electrolyte membrane may be properly
determined in consideration of the characteristics of the obtained
fuel cell, and is not particularly limited. The thickness of the
electrolyte membrane is ordinarily approximately 5 to 300 .mu.m.
The balance between the strength during the manufacturing process
of the membrane, the durability during usage, and output
performance during use can be properly controlled, when the
thickness of the electrolyte membrane is within such a range.
[0211] (Gas Diffusion Layer)
[0212] The gas diffusion layers (the anode gas diffusion layer 4a
and the cathode gas diffusion layer 4c) have the function of
promoting the diffusion of the gas (the fuel gas or the oxidant
gas) supplied through the gas passages (6a and 6c) of the separator
to the catalyst layers (3a and 3c), as well as the function as the
electronic conduction path.
[0213] A material composing a substrate of the gas diffusion layers
(4a and 4c) is not particularly limited, and can be properly
referred to the conventionally known knowledge. Examples thereof
include sheet-like materials with conductivity and porosity, such
as fabrics made of carbon, paper-like paper-making material, felt
and unwoven fabric. The thickness of the substrate may be properly
determined in consideration of the characteristics of the obtained
gas diffusion layer, and it may be approximately 30 to 500 .mu.m.
When the thickness of the substrate is a value within such a range,
the balance between the mechanical strength and the diffusivity of
gas, water and the like can be properly controlled.
[0214] The gas diffusion layer preferably contains water-repellent
agent with the aim of enhancing water repellency to prevent a
flooding phenomenon and the like. Examples of the water-repellent
agents include, but not particularly limited to, fluorine-based
polymer materials such as polytetrafluoroethylene (PTFE),
polyfluorovinylidene (PVdF), polyhexafluoropropylene and
tetrafluoroethylene-hexafluoropropylene copolymer (FEP), as well as
polypropylene and polyethylene.
[0215] Also, in order to further improve water repellency, the gas
diffusion layer may be such as to have a carbon particle layer
comprising an aggregate of carbon particles containing the
water-repellent agent (a microporous layer; MPL, not shown in the
drawings) on the catalyst layer side of the substrate.
[0216] The carbon particles contained in the carbon particle layer
are not particularly limited, and conventionally known materials
such as carbon black, graphite and expanded graphite may be
properly adopted. Among them, carbon black such as oil furnace
black, channel black, lamp black, thermal black and acetylene black
may be preferably used by reason of having excellent electron
conductivity and large specific surface area. The average particle
size of the carbon particles is preferably approximately 10 to 100
nm. Thus, high drainage by capillary force is obtained, and the
contact with the catalyst layer also can be improved.
[0217] Examples of the water-repellent agent used for the carbon
particle layer include the same as the above-mentioned
water-repellent agent. Above all, the fluorine-based polymer
materials may be preferably used by reason of being excellent in
water repellency and corrosion resistance during the electrode
reaction.
[0218] The mixing ratio between the carbon particles and the
water-repellent agent in the carbon particle layer should be
approximately 90:10 to 40:60 at weight ratio (carbon
particles:water-repellent agent) in consideration of the balance
between the water repellency and the electron conductivity.
Incidentally, also the thickness of the carbon particle layer is
not particularly limited and may be properly determined in
consideration of the water repellency of the obtained gas diffusion
layer.
[0219] (Method for Producing Membrane Electrode Assembly)
[0220] The method for producing the membrane electrode assembly is
not particularly limited, and a conventionally known method can be
used. For example, it is possible to use the method of transferring
by means of a hot press or coating the catalyst layer on the solid
polymer electrolyte membrane, drying it, and joining the gas
diffusion layer to it, or the method of preparing two gas diffusion
electrodes (GDE) by previously coating the catalyst layer on one
side of the microporous layer side of the gas diffusion layer (or
the substrate layer when the microporous layer is not included) and
drying it, and joining these gas diffusion electrodes to both sides
of the solid polymer electrolyte membrane by means of a hot press.
The coating and assembly conditions of the hot press and the like
may be properly adjusted, depending on the kinds (perfluorosulfonic
acid-based and hydrocarbon-based) of the solid polymer electrolyte
membrane and the polymer electrolyte in the catalyst layer.
[0221] (Separator)
[0222] The separator has the function of electrically connecting
each cell in series when configuring the fuel cell stack by
connecting in series a plurality of single cells of the fuel cell
such as a polymer electrolyte fuel cell. Also, the separator has
the function of serving as a partition wall for separating fuel
gas, oxidant gas and refrigerant from each other. In order to
secure the passages for them, as described above, a gas passage and
a refrigerating passage are preferably provided on each of the
separators. As the material for composing the separators,
conventionally known materials, for example, carbon such as dense
carbon graphite and carbon plate, or metals such as stainless steel
can be properly adopted without any limitation. The thickness and
size of the separators, and the shape and size of each passage to
be provided are not particularly limited, and may be properly
determined in consideration of the desired output performance of
the obtained fuel cell.
[0223] Moreover, in order for the fuel cell to be able to generate
a desired voltage, a fuel cell stack, which has a structure such as
to connect in series a plurality of layers of membrane electrode
assemblies through the separators, may be formed. The shape of the
fuel cell is not particularly limited, and may be properly
determined so as to obtain battery characteristics such as the
desired voltage.
[0224] The above-mentioned PEFC and membrane electrode assembly use
the catalyst layer excellent in power generation performance and
durability. Accordingly, the PEFC and the membrane electrode
assembly are excellent in power generation performance and
durability.
[0225] The PEFC according to the present embodiment and the fuel
cell stack using the same can be, for example, mounted on a motor
vehicle as a drive power source.
EXAMPLES
[0226] The effect of the present invention will be described by
using the following examples and comparative examples. However, the
technical scope of the present invention should not be construed to
be limited to the following examples. Meanwhile, in the following
examples, the operations are performed at room temperature
(25.degree. C.) unless it is specifically described otherwise.
Furthermore, "%" and "parts" indicate "% by weight" and "parts by
weight", respectively, unless specifically described otherwise.
Reference Example 1
[0227] A carbon material A was prepared, according to the method
described in WO 2009/75264 A. As for the carbon material A obtained
as above, pore volumes of micropores and mesopores, mode diameters
of micropores and mesopores and BET specific surface area were
measured. As a result, the pore volume of micropores was 1.04 cc/g,
the pore volume of mesopores was 0.92 cc/g, the mode diameter of
micropores was 0.65 nm, the mode diameter of mesopores was 1.2 nm,
and the BET specific surface area was 1770 m.sup.2/g.
[0228] A carrier A (catalyst carrier precursor) with an average
particle size of 100 nm was prepared by heating the obtained carbon
material A to 1850.degree. C. at a temperature increase rate of
500.degree. C./hour in an argon atmosphere, and then maintaining it
at the same temperature for 5 minutes.
[0229] As a result of measuring the R value and R' value of the
carrier A, they were found to be 2.15 and 0.35, respectively.
[0230] As for the carrier A obtained as above, pore volumes of
micropores and mesopores, mode diameters of micropores and
mesopores and BET specific surface area were measured. As a result,
the pore volume of micropores was 0.61 cc/g, the pore volume of
mesopores was 0.68 cc/g, the mode diameter of micropores was 0.75
nm, the mode diameter of mesopores was 1.2 nm, and the BET specific
surface area was 1226 m.sup.2/g.
[0231] The carrier A was used and platinum (Pt) with an average
particle size of 3.3 nm was supported as a catalytic metal on this
carrier A so that the carrying rate was 30% by weight to obtain a
catalyst powder A. Namely, 46 g of the carrier A was immersed in
1000 g of a dinitrodiammine platinum nitric acid solution with a
platinum concentration of 4.6% by weight (platinum content: 46 g)
and the mixture was stirred, then 100 ml of 100% ethanol was added
as a reducing agent. This solution was stirred and mixed at the
boiling point for 7 hours, and platinum was supported on the
carrier A. Then, the mixture was filtered and dried to obtain a
catalyst powder with a carrying rate of 30% by weight. Thereafter,
the catalyst powder was maintained in a hydrogen atmosphere at a
temperature of 900.degree. C. for 1 hour, to obtain a catalyst
powder A with an average particle size of 100 nm. As a result of
measuring the R value and R' value of this catalyst powder A, they
were found to be 2.15 and 0.35, respectively.
[0232] As for the catalyst powder A obtained as above, pore volumes
of micropores and mesopores, mode diameters of micropores and
mesopores and BET specific surface area were measured. As a result,
the pore volume of micropores was 0.65 cc/g carrier, the pore
volume of mesopores was 0.48 cc/g carrier, the mode diameter of
micropores was 0.75 nm, the mode diameter of mesopores was 1.20 nm,
and the BET specific surface area was 1115 m.sup.2/g. Also, the BET
specific surface area of the carrier in the catalyst powder A is
1226 m.sup.2/g carrier.
[0233] Furthermore, in the catalyst powder A, the volume ratio of a
water vapor adsorption amount compared to a nitrogen adsorption
amount at a relative pressure of 0.5 in adsorption isotherm was
0.080.
Reference Example 2
[0234] A carrier B (catalyst carrier precursor) with a BET specific
surface area of 1378 m.sup.2/g was prepared by heating the carbon
material A obtained from Reference Example 1 to 1700.degree. C. at
a temperature increase rate of 500.degree. C./hour in an argon
atmosphere, and then maintaining it at the same temperature for 5
minutes.
[0235] As a result of measuring the R value and R' value of the
carrier B, they were found to be 1.99 and 0.42, respectively.
[0236] Furthermore, as for the carrier B obtained as above, average
particle size (diameter), pore volumes of micropores and mesopores,
mode diameters of micropores and mesopores and BET specific surface
area were measured. As a result, the average particle size
(diameter) was 91.5 nm, the pore volume of micropores was 0.43 cc/g
carrier, the pore volume of mesopores was 0.69 cc/g carrier, the
mode diameter of micropores was 0.66 nm, the mode diameter of
mesopores was 2.8 nm, and the BET specific surface area was 1378
m.sup.2/g for the carrier B.
[0237] Catalyst powder was prepared in the same manner as Reference
Example 1 by using the carrier B, and a catalyst powder B having
average particle size of 105 nm was obtained. As a result of
measuring the R value and R' value of the catalyst powder B, they
were found to be 1.99 and 0.42, respectively.
[0238] As for the catalyst powder B obtained as above, pore volumes
of micropores and mesopores, mode diameters of micropores and
mesopores and BET specific surface area were measured. As a result,
the pore volume of micropores was 0.74 cc/g carrier, the pore
volume of mesopores was 0.52 cc/g carrier, the mode diameter of
micropores was 0.72 nm, the mode diameter of mesopores was 1.66 nm,
and the BET specific surface area was 1234 m.sup.2/g.
Reference Example 3
[0239] A carrier C (catalyst carrier precursor) with a BET specific
surface area of 1522 m.sup.2/g was prepared by heating the carbon
material A which has been obtained in Reference Example 1 to
1600.degree. C. at a temperature increase rate of 500.degree.
C./hour in an argon atmosphere, and then maintaining it at the same
temperature for 5 minutes.
[0240] As a result of measuring the R value and R' value of the
carrier C, they were found to be 1.81 and 0.50, respectively.
[0241] Furthermore, as for the carrier C obtained as above, average
particle size (diameter), pore volumes of micropores and mesopores,
mode diameters of micropores and mesopores and BET specific surface
area were measured. As a result, the average particle size
(diameter) was 89 nm, the pore volume of micropores was 0.73 cc/g
carrier, the pore volume of mesopores was 1.17 cc/g carrier, the
mode diameter of micropores was 0.73 nm, the mode diameter of
mesopores was 2.4 nm, and the BET specific surface area was 1522
m.sup.2/g for the carrier C.
[0242] Catalyst powder was prepared in the same manner as Reference
Example 1 by using the carrier C and a catalyst powder C having
average particle size of 90 nm was obtained. As a result of
measuring the R value and R' value of the catalyst powder C, they
were found to be 1.81 and 0.50, respectively.
[0243] As for the catalyst powder C obtained as above, pore volumes
of micropores and mesopores, mode diameters of micropores and
mesopores and BET specific surface area were measured. As a result,
the pore volume of micropores was 0.84 cc/g carrier, the pore
volume of mesopores was 1.1 cc/g carrier, the mode diameter of
micropores was 0.71 nm, the mode diameter of mesopores was 1.66 nm,
and the BET specific surface area of the catalyst carrier was 1522
m.sup.2/g.
Reference Example 4
[0244] As a result of measuring the R value and R' value of the
carrier D in which the carbon material A obtained from Reference
Example 1 is used, they were found to be 1.64 and 0.61,
respectively. Furthermore, as for the carrier D obtained
accordingly, average particle size (diameter), pore volumes of
micropores and mesopores, mode diameters of micropores and
mesopores and BET specific surface area were measured. As a result,
the average particle size (diameter) was 91.5 nm, the pore volume
of micropores was 1.04 cc/g carrier, the pore volume of mesopores
was 1.23 cc/g carrier, the mode diameter of micropores was 0.65 nm,
the mode diameter of mesopores was 2.1 nm, and the BET specific
surface area was 1768 m.sup.2/g for the carrier D.
[0245] Catalyst powder was prepared in the same manner as Reference
Example 1 by using the carrier D and a catalyst powder D was
obtained. As a result of measuring the R value and R' value of the
catalyst powder D, they were found to be 1.64 and 0.61,
respectively.
Reference Example 5
[0246] A carrier E was prepared by heating the carbon material A
which has been obtained in Reference Example 1 to 1300.degree. C.
at a temperature increase rate of 500.degree. C./hour in an argon
atmosphere, and then maintaining it at the same temperature for 5
minutes. As a result of measuring the R value and R' value of the
carrier E, they were found to be 1.75 and 0.66, respectively.
Furthermore, as for the carrier E obtained accordingly, average
particle size (diameter), pore volumes of micropores and mesopores,
mode diameters of micropores and mesopores and BET specific surface
area were measured. As a result, the average particle size
(diameter) was 91.5 nm, the pore volume of micropores was 1.06 cc/g
carrier, the pore volume of mesopores was 1.21 cc/g carrier, the
mode diameter of micropores was 0.66 nm, the mode diameter of
mesopores was 2.1 nm, and the BET specific surface area was 1768
m.sup.2/g for the carrier E.
[0247] Catalyst powder was prepared in the same manner as Reference
Example 1 by using the carrier E and a catalyst powder E was
obtained. As a result of measuring the R value and R' value of the
catalyst powder E, they were found to be 1.75 and 0.66,
respectively.
[0248] In the catalyst powder E, the volume ratio of a water vapor
adsorption amount compared to a nitrogen adsorption amount at a
relative pressure of 0.5 in adsorption isotherm was 8.4.
Reference Example 6
[0249] Ketjen black (EC300J) (BET specific surface area of 715
m.sup.2/g) was used as a carrier F. As a result of measuring the R
value and R' value of the carrier F, they were found to be 1.78 and
0.74, respectively. Furthermore, as for the carrier F obtained as
above, the average particle size (diameter), pore volumes of
micropores and mesopores, mode diameters of micropores and
mesopores and BET specific surface area were measured. As a result,
the average particle size (diameter) was 53 nm, the pore volume of
micropores was 0.35 cc/g carrier, the pore volume of mesopores was
0.49 cc/g carrier, the mode diameter of micropores was 0.45 nm, the
mode diameter of mesopores was 2.2 nm, and the BET specific surface
area was 715 m.sup.2/g for the carrier F.
[0250] Catalyst powder was prepared in the same manner as Reference
Example 1 by using the carrier F and a catalyst powder F was
obtained. In the catalyst powder F, the volume ratio of a water
vapor adsorption amount compared to a nitrogen adsorption amount at
a relative pressure of 0.5 in adsorption isotherm was 0.15.
Experiment 1: Evaluation of Platinum Coating
[0251] For a case in which platinum is supported, in an amount of
50% by weight relative to carrier weight, on the carriers B and C
which have been prepared in Reference Examples 2 and 3 and the
carrier F which has been prepared in Reference Example 6, the
platinum specific surface area (COMSA) was measured by CO
adsorption method. The results are shown in FIG. 4.
[0252] Based on FIG. 4, it is found that the carriers B and C
(carbon powder) with a BET specific surface area of at least 900
m.sup.2/g have a significantly higher platinum specific surface
area compared to the carrier F with a BET specific surface area of
less than 900 m.sup.2/g. Since the BET specific surface area of a
catalyst is similar to the BET specific surface area of a carrier,
it is believed that the electric double layer capacity of a carrier
can be significantly improved as the BET specific surface area of a
catalyst is 900 m.sup.2/g or more.
Experiment 2: Evaluation of Durability
[0253] The catalyst powders A to E were used for durability
evaluation as described below. The results are shown in Table 3
below. Namely, a three-electrode type electrochemical cell was
used, and as a potentiostat, the electrochemical measuring system
HZ-5000+HR301 manufactured by HOKUTO DENKO CORP. was used. As a
working electrode, a glassy carbon rotating electrode (GC-RDE)
(.phi.(diameter)=5 mm) was used. Then, after coating with an ink,
which has been obtained by dispersing each catalyst powder prepared
in Reference Example, dispersed in a mixed solvent of water and
1-propanol as a dispersion medium to have dry film thickness of 1
.mu.m followed by drying, the resulting electrode was used. As a
counter electrode, carbon was used. As a reference electrode, a
reversible hydrogen electrode (RHE) was used. As an electrolyte
liquid, 0.1 M perchloric acid saturated with O.sub.2 was used. The
measurement was performed at 60.degree. C. Calculation of an
effective surface area of catalyst (ECA) was performed by cyclic
voltammetry (CV). Before performing the measurement, potential
injection was performed for 30 seconds at potential of 1.0 V. After
that, the potential range of from 1.0 to 1.5 V was increased (1
second) and then decreased (1 second) at potential sweep rate of
0.5 V/s, and this operation was employed as one cycle (2
seconds/cycle). As a result of repeating this potential cycle, the
peak potential of quinone-hydroquinone cathodic current around 0.6
V measured by cyclic voltammetry is shifted to a lower voltage
side, in accordance with increasing potential cycle. From the
change in this cathodic current, the carbon state and a change in
electric double layer capacity were approximately obtained.
Specifically, the number of cycles that can be performed until the
potential of cathodic current is 0.5 V or less is determined as an
indicator of durability.
TABLE-US-00003 TABLE 3 Number of cycles to have peak potential of
0.5 V or less Catalyst for cathodic powder R' value R value current
Reference A 0.35 2.15 4159 Example 1 Reference B 0.42 1.99 3766
Example 2 Reference C 0.50 1.81 1724 Example 3 Reference D 0.61
1.64 1350 Example 4 Reference E 0.66 1.75 778 Example 5
[0254] It can be seen from Table 3 that the catalyst powder A to C
of Reference Examples 1 to 3 have, compared to the catalyst powder
D and E of Reference Examples 4 and 5, large number of cycles for
having lowered cathodic current. Based on this, it is considered
that a catalyst with R' (D'/G intensity ratio) of 0.6 or less has a
small decrease in electric double layer capacity, and thus it can
maintain the activity at significantly high level (durability is
excellent).
Example 1
[0255] The catalyst powder A prepared in Reference Example 1 was
subjected to a treatment with an oxidative solution for adding an
acidic group. The catalyst powder A was immersed for 2 hours at
80.degree. C. in 3.0 mol/L aqueous solution of nitric acid. After
that, it was filtered and dried to obtain the catalyst powder A'
(catalyst) having an acidic group.
[0256] Furthermore, as for the catalyst powder A', pore volumes of
micropores and mesopores, mode diameters of micropores and
mesopores and BET specific surface area were measured. As a result,
the pore volume of micropores was 0.61 cc/g carrier, the pore
volume of mesopores was 0.68 cc/g carrier, the mode diameter of
micropores was 0.75 nm, the mode diameter of mesopores was 1.2 nm,
and the BET specific surface area was 1115 m.sup.2/g for the
catalyst powder A'. Also, the BET specific surface area of the
carrier in the catalyst powder A' is 1226 m.sup.2/g carrier.
[0257] In the catalyst powder A', the volume ratio of a water vapor
adsorption amount compared to a nitrogen adsorption amount at a
relative pressure of 0.5 in adsorption isotherm was 0.20.
[0258] The catalyst powder A' and an ionomer dispersion liquid
(perfluorocarbon sulfonic acid-based polymer, Aciplex (registered
trademark) SS700, EW=700 g/eq (g/mol), manufactured by Asahi Kasei
Corporation) as a polymer electrolyte were mixed so that the weight
ratio of the polymer electrolyte to the carbon carrier was 0.6.
Furthermore, a solvent containing water and n-propyl alcohol
(weight ratio of 8:2) was added such that the solid content ratio
(Pt+carbon carrier+polymer electrolyte) is 7% by weight to prepare
a cathode catalyst ink.
[0259] Separately, ketjen black EC300J (manufactured by Ketjen
Black International) was subjected to a heat treatment at 2000 to
3000.degree. C. under argon atmosphere for 5 to 20 hours.
Accordingly, graphite ketjen black (particle size: 30 to 60 nm) was
prepared as a carrier. By using this carrier, platinum (Pt) with an
average particle size of 2.5 nm was supported as a catalytic metal
so that the carrying rate was 50% by weight to obtain a catalyst
powder. This catalyst powder and an ionomer dispersion liquid
(Nafion (registered trademark) D2020, EW=1100 g/eq (g/mol),
manufactured by DuPont) as a polymer electrolyte were mixed so that
the weight ratio of the polymer electrolyte to the carbon carrier
was 0.9. In addition, a solvent containing water and n-propyl
alcohol (weight ratio of 5:5) was added thereto such that the solid
content ratio (Pt+carbon carrier+ionomer) is 7% by weight to
prepare an anode catalyst ink.
[0260] Next, a gasket (manufactured by Teijin Dupont, Teonex, film
thickness: 25 .mu.m (adhesive layer: 10 .mu.m)) was provided around
the both sides of a polymer electrolyte membrane (manufactured by
Dupont, NAFION NR211, film thickness: 25 .mu.m). Subsequently, the
exposed part of one side of the polymer electrolyte membrane was
coated with the cathode catalyst ink in a size of 5 cm.times.2 cm
by spray coating method. The catalyst ink was dried by keeping the
stage of spray coating at 60.degree. C. for 1 minute to obtain a
cathode catalyst layer which has film thickness (dry film
thickness) of 10 .mu.m. The platinum carrying amount at that time
was 0.15 mg/cm.sup.2. Then, spray coating on the electrolyte
membrane and heat treatment were performed as in the cathode
catalyst layer to form an anode catalyst layer which has film
thickness (dry film thickness) of 10 .mu.m.
[0261] Both sides of the resulting laminated body were sandwiched
between gas diffusion layers (24BC, manufactured by SGL CARBON AG)
to obtain a membrane electrode assembly (1) (MEA (1)).
Example 2
[0262] The membrane electrode assembly (2) (MEA (2)) was obtained
in the same manner as Example 1 except that, for producing a
cathode catalyst ink, mixing was carried out so that the weight
ratio of the polymer electrolyte to the carbon carrier was 0.5.
Comparative Example 1
[0263] The membrane electrode assembly (3) (MEA (3)) was obtained
in the same manner as Example 1 except that, for producing a
cathode catalyst ink, the catalyst powder A was used instead of the
catalyst powder A'.
Comparative Example 2
[0264] The membrane electrode assembly (4) (MEA (4)) was obtained
in the same manner as Example 1 except that the cathode catalyst
ink was prepared as described below.
[0265] The catalyst powder A and an ionomer dispersion liquid
(Nafion (registered trademark) D2020, EW=1100 g/eq (g/mol),
manufactured by DuPont)) were mixed so that the weight ratio of the
polymer electrolyte to the carbon carrier was 0.9. Furthermore, a
solvent containing water and n-propyl alcohol (weight ratio of 6:4)
was added such that the solid content ratio (Pt+carbon
carrier+polymer electrolyte) is 7% by weight to prepare a cathode
catalyst ink.
Comparative Example 3
[0266] The carrier G (Black pearls 2000, manufactured by Cabot
Corporation) was used and platinum (Pt) with an average particle
size of 3.3 nm was supported as a catalytic metal on this carrier A
so that the carrying rate was 50% by weight to obtain a catalyst
powder G. Namely, 46 g of the carrier G was immersed in 1000 g of a
dinitrodiammine platinum nitric acid solution with a platinum
concentration of 4.6% by weight (platinum content: 46 g) and the
mixture was stirred, then 100 ml of 100% ethanol was added as a
reducing agent. This solution was stirred and mixed at the boiling
point for 7 hours, and platinum was supported on the carrier G.
Then, the mixture was filtered and dried to obtain a catalyst
powder with a carrying rate of 50% by weight. Thereafter, the
catalyst powder was maintained in a hydrogen atmosphere at a
temperature of 900.degree. C. for 1 hour, to obtain a catalyst
powder G. As a result of measuring the R' value of this catalyst
powder G, it was found to be 0.85. the BET specific surface area
was 1076 m.sup.2/g for the catalyst powder G. Also, the BET
specific surface area of the carrier in the catalyst powder G is
1290 m.sup.2/g carrier.
[0267] In the catalyst powder G, the volume ratio of a water vapor
adsorption amount compared to a nitrogen adsorption amount at a
relative pressure of 0.5 in adsorption isotherm was 0.40.
[0268] The membrane electrode assembly (5) (MEA (5)) was obtained
in the same manner as Comparative Example 2 except that, for
producing a cathode catalyst ink, the catalyst powder G was used
instead of the catalyst powder A.
[0269] [Evaluation of Voltage Drop Caused by Oxygen Transport]
Experiment 3: Evaluation of Oxygen Transport Resistance
[0270] By using the membrane electrode assemblies (1) and (2) which
have been produced in the above Examples 1 to 2 and the membrane
electrode assemblies (3) to (5) which have been produced in the
above Comparative Examples 1 to 3, an evaluation of oxygen
transport resistance was carried out in accordance with the method
described in T. Mashio et al., ECS Trans., 11, 529, (2007).
[0271] Specifically, the limiting current density (A/cm.sup.2) was
measured by using diluted oxygen. At that time, from the slope of
the limiting current density (A/cm.sup.2) relative to the partial
pressure of oxygen (kPa), the gas transport resistance (s/m) was
calculated. The results are shown in Table 4.
TABLE-US-00004 TABLE 4 Ratio of BET water vapor specific R' value
adsorption Oxygen surface (D'/G amount/nitrogen transport Catalyst
area intensity adsorption resistance powder (m.sup.2/g) ratio)
amount (s/m) Example 1 A' 1226 0.35 0.20 8.7 Example 2 A' 1226 0.35
0.20 10.6 Comparative A 1226 0.35 0.080 17.0 Example 1 Comparative
A 1226 0.35 0.080 20.2 Example 2 Comparative G 1290 0.85 0.40 12.2
Example 3
[0272] It can be seen from Table 4 that the MEAs (1) and (2) of
Examples 1 and 2 have lower oxygen transport resistance compared to
the MEAs (3) to (5) of Comparative Examples 1 to 3. Thus, it is
considered that the gas transportability can be improved by using
the fuel cell catalyst layer of the present invention.
[0273] The present application is based on Japanese Patent
Application No. 2014-220579 filed on Oct. 29, 2014, and its
enclosure is entirely incorporated herein by reference.
* * * * *